Suntrap ST-250-48 Quick start guide

Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
Solar Hot Water
Installation Instructions
and Owners Manual
AS 2712 Lic 21687
SAI Global
WMKA Lic 21688
SAI Global
This Manual Covers 10 sys em models:
Elec ric Boos Models:
ST-160-16: ST-250-32: ST-315-32: ST-250-48: ST-315-48
December 2010 issue 10.4
Suntrap Pty Ltd
PO Box 3164
Dural
NSW 21 8
Tel: [phone]
Gas Boos Models:
ST-160NG21-16 / ST-160LPG21-16: ST-250NG26-32 / ST-250LPG26-32
ST-315NG26-32 / ST-315LPG26-32: ST-250NG26-48 / ST-250LPG26-48
ST-315NG26-48 / ST-315LPG26-48
Plumbers/Ins allers – Please read his Manual
before a emp ing he ins alla ion of he Sun rap
Solar Ho Wa er Sys em

1
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
Contents
1 Suntrap Solar Hot Water systems - Renewable Energy 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
Completed installation views of assembled parts
6 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
1 Specifications of the Suntrap Evacuated U Tube Solar Collector SLU-1 00/16
16 Warranty and Refund Policy

2
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
AS/NZS 4234:2007 Clima ic Zones
Used in determining the Renewable Energy Certificates across Australia
1. Renewable Energy Certificates
Calcula ed Renewable Energy for Sun rap P y Solar Ho wa er Produc s
The following table presents the calculated RECS and annual energy saving for the different
Suntrap solar configurations using SLU-1 00/16 type evacuated tube collectors
Configura ion
Annual Energy Saving (%) 10 Year Renewable Energy
Cer ifica e Alloca ion
Zone 1 Zone 2 Zone 3 Zone 4 Zone 1 Zone 2 Zone 3 Zone 4
ST-160NG21-16 &
ST-160LPG21-16
ST-250NG26-32 &
ST-250LPG26-32
ST-250NG26-48 &
ST-250LPG26-48
ST-315NG26-32 &
ST-315LPG26-32
ST-315NG26-48 &
ST-315LPG26-48
ST-160-16
ST-250-32
ST-250-48
ST-315-32
ST-315-48
53 61 53 41 22 22 22 18
64 75
78
64 49 37 38 37 30
38
38
45
44
45
63
71 58 30 25
30
30
31
29
30
45 45
45
29
15
16
57 11
29
49
33
78
37
63
37 37
35
35 33 35
24
29
57
71
82
63
77
42
35
69
15
84
83 93 83
83
70 70
93 82
56
74
63
87
73
71
77
88
RENEWABLE ENERGY CERTIFICATES

3
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
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 E) on the Solar control kit.
To urn on he wa er hea er
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 E) 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).
Hea er Boos con rol
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.
Wa er pressure
The water pressure used with this Solar Hot Water system must be a minimum of 200kpa.
Tank Sizes
160 litre 1140mm(h) x 80mm dia. 2 0 litre 1620mm(h) x 80mm dia. 31 litre 1980mm(h) x 80mm dia.
Solar collec or roof space required
1 collector 1.2m(w) x 1.8m(h) 2 collectors 2.4m(w) x 1.8m(h) 3 collectors 3.6m(w) x 1.8m(h)
No e:
All ins alla ions mus be carried ou by au horised plumbers or o her au horised persons.
Ins aller - Please familiarise yourself wi h all he diagrams and pic ures before s ar ing o connec he sys em
oge her. Ins alla ion ins ruc ions begin a sec ion 10.
Some diagrams/pic ures are represen a ive only and some pic ures are shown before pipe insula ion has
been fi ed for clari y. To comply wi h AS2712 cer ifica ion, he plumbing be ween he solar ho wa er ank
and he solar collec ors mus be ins alled using 12mm in ernal pipe diame er wi h insula ion hickness of
40mm on he inle pipe and 12mm in ernal pipe diame er wi h insula ion hickness of 40mm on he ou le
pipe, bo h pipes using insula ion ma erial o ISOpipe insula ion s andards. For Gas Boos ed sys ems he
pipe be ween he Solar prehea ank and Gas Boos er mus use Armaflex 32mm hickness insula ion.
2. Abou your Sun rap Solar Ho Wa er Sys em
Congra ula ions 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. Three 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 160, 2 0 or
31 litres with either a 3.6 KW heater, or a Bosch 21e/26e gas heater.
The Solar Tanks are suitable for installations either inside or outdoors. 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 Off Peak 1 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.)
Tempera ure adjus men
On electrically boosted systems, the solar tank thermostat determines the tank temperature during off-peak boosting and may be
adjusted by a licensed tradesperson if required. 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 control the solar pump to circulate the water
when there is a temperature difference of 9 degrees centigrade or more between the tank temperature and the solar collector
outlet temperature, or when the temperature of the solar collectors are +3 degrees centigrade (to prevent the solar collectors
from freezing).
The Solar Tank thermostat temperature has been factory set and should not require adjustment. The water heater is supplied with
a Pressure and Temperature Relief valve (PTR 8 0 Valve) which must not be tampered with.
Safe y
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 urn off he ho wa er

4
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
Thermostat setting (Electric Boost) – Higher tank temperatures during boost times 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.
Holidays – 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 E to the off position, turn off the ‘mains water in’ at the DuoValve at point C, switch off the ‘off peak’ booster
supply. If freezing conditions are expected while away, leave the solar controller switched on and the Shut off ball-valve (point E)
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.
Ins alla ion No es
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 26 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 collector.
The tank must be located onto a firm base and sufficient space must be provided around the solar hot water tank for servicing.
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 40mm all the way to
the solar collectors and back to the solar hot water tank, and for Gas Boosted systems use insulation thickness of 32mm on the
pipe between the Solar Preheat Tank and Gas Booster), brass fittings, W62 and W63 brass fittings, Conetite unions, and/or
brass fittings with copper olives.
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 3 00.4.
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 3 00.4). Draining of the ‘safe tray’ must also comply with AS/NZS 3 00.4.
Caring for your sys em
At the top of the Solar hot water tank there is an 8 0kpa 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 6 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 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 elow)
Collec or 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.
Wa er no ho 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 conditions are good – 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 31 litre tank, with a
3.6 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 Expansion Control Valve (Point L) – Arrangements other than Off Peak 1 electrical boosting, especially in
Summer, 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, resulting in excessive water exit from the Expansion Control
Valve and/or the PTR Valve. Off Peak 1 secondary boosting ensures minimal hours of electrical boosting and maximises the benefits
and efficiency of solar heating obtained from the sun. Suntrap systems are certified to use Off Peak 1 electrical boosting.

Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
Mains wa er supply:
The system is fitted with a water pressure limiting valve (connected to the DuoValve at point C). This ensures that the tank is never
under excess pressure. The valve is rated at 00 kpa and must never be changed for a higher rating.
Ins alla ion of he Solar Ho Wa er Tank and Solar Collec ors:
The Solar Hot water tank and the Solar Collectors are provided as part of the Suntrap Solar Hot water kit, and all components must
be installed, maintained and operated as per instructions otherwise all warranties are null and void.
3. Suntrap Solar Hot Water Kits - Parts Supplied
The Sun rap Solar Ho Wa er Ki s:
All kit components must be used as per supplied. The kit of parts include sub-assemblies which must be fitted complete as supplied.
Suntrap Pty Ltd reserves the right to vary the kit contents and components at its discretion at any time.
There are 10 Sun rap Ki s as follows:
(Please note that there are 16 glass evacuated tubes per solar collector.)
Roof space required for Solar collec ors:
1 x solar collec or 1.2 me ers wide x 1.8 me ers high
2 x solar collec ors 2.4 me ers wide x 1.8 me ers high
3 x solar collec ors 3.6 me ers wide x 1.8 me ers high
Elec ric Boos Models:
ST-160-16: 160 li re solar ho wa er ank wi h 1 solar collec or and elec ric boos - 1140mm (h) x 80mm (dia)
ST-250-32: 250 li re solar ho wa er ank wi h 2 solar collec ors and elec ric boos - 1620mm (h) x 80mm (dia)
ST-315-32: 315 li re solar ho wa er ank wi h 2 solar collec ors and elec ric boos - 1980mm (h) x 80mm (dia)
ST-250-48: 250 li re solar ho wa er ank wi h 3 solar collec ors and elec ric boos - 1620mm (h) x 80mm (dia)
ST-315-48: 315 li re solar ho wa er ank wi h 3 solar collec ors and elec ric boos - 1980mm (h) x 80mm (dia)
Gas Boos Models:
ST-160NG21-16 / ST-160LPG21-16: 160 li re solar ho wa er ank wi h 1 solar collec or and gas boos - 1140mm (h) x 80mm (dia)
ST-250NG26-32 / ST-250LPG26-32: 250 li re solar ho wa er ank wi h 2 solar collec ors and gas boos - 1620mm (h) x 80mm (dia)
ST-315NG26-32 / ST-315LPG26-32: 315 li re solar ho wa er ank wi h 2 solar collec ors and gas boos - 1980mm (h) x 80mm (dia)
ST-250NG26-48 / ST-250LPG26-48: 250 li re solar ho wa er ank wi h 3 solar collec ors and gas boos - 1620mm (h) x 80mm (dia)
ST-315NG26-48 / ST-315LPG26-48: 315 li re solar ho wa er ank wi h 3 solar collec ors and gas boos - 1980mm (h) x 80mm (dia)
For 1 x solar collec or (ST-160-16: ST-160NG21-16 / ST-160LPG21-16)
Par /n – SET116 1 x complete Suntrap evacuated tube Solar Collector with 16 x evacuated glass tubes
Par /n – SSF001 4 x square sections of stainless steel for Roof Frame (top, bottom and 2 sides)
Par /n – MOU001 4 x brackets and 24 screws for assembling the Roof Frame, 2 x left hand, and 2 x right hand
collector brackets to connect the solar collector to the Roof Frame, 4 x nuts and bolts and
4 x screws for the collector brackets, 4 x stainless steel straps for attaching the Roof Frame
to the roof, 4 x screws for attaching the stainless steel straps to the Roof Frame, 8 x roof screws
for attaching stainless steel straps to the roof rafters.
There are no interconnecting solar collector components required for this system

6
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
For 2 x solar collec ors (ST-2 0-32: ST-31 -32: ST-2 0NG26-32 / ST- 2 0LPG26-32: ST-31 NG26-32 / ST-31 LPG26-3 )
Par /n – SET232 2 x complete Suntrap evacuated tube Solar Collectors, each with 16 x evacuated glass tubes
Par /n – SSF002 4 x square sections of stainless steel for Roof Frame (top, bottom and 2 sides)
Par /n – MOU002 4 x brackets and 24 screws for assembling the Roof Frame, 4 x left hand, and 4 x right hand
collector brackets to connect the solar collectors to the Roof Frame, 8 x nuts and bolts and
8 x screws for the collector brackets, 4 x stainless steel straps for attaching the Roof Frame
to the roof, 4 x screws for attaching the stainless steel straps to the Roof Frame, 8 x roof screws
for attaching stainless steel straps to the roof rafters.
Par /n – FCS002 2 x couplings used to connect the solar collectors together (point N). Includes: 2 x ¾”F x 3/4” CTI
unions, 1 x 82mm x 20mm diameter copper pipe
FCS002 – Coupling componen s used
o connec 2 x Solar Collec ors oge her
For 3 x solar collec ors (ST-2 0-48: ST-31 -48: ST-2 0NG26-48 / ST-2 0LPG26-48: ST-31 NG26-48 / ST-31 LPG26-48)
Par /n – SET348 3 x complete Suntrap evacuated tube Solar Collectors, each with 16 x evacuated glass tubes
Par /n – SSF003 4 x square sections of stainless steel for Roof Frame (top, bottom and 2 sides)
Par /n – MOU003 4 x brackets and 24 screws for assembling the Roof Frame, 6 x left hand, and 6 x right hand
collector brackets to connect the solar collectors to the Roof Frame, 12 x nuts and bolts and
12 x screws for the collector brackets, 4 x stainless steel straps for attaching the Roof Frame to
the roof, 4 x screws for attaching the stainless steel straps to the Roof Frame, 8 x roof screws
for attaching stainless steel straps to the roof rafters.
Par /n – FCS003 4 x couplings used to connect the solar collectors together (points M and N). Includes: 4 x ¾”F x ¾”
CTI Conetite unions, 2 x 82mm x 20mm diameter copper pipes.
FCS003 – Coupling componen s used o
Connec he 3 x Solar Collec ors oge her

7
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
Par /n – EST160 1 x 160 litre Everlast stainless steel solar hot water tank with a single 3.6 KW heating element
or
Par /n – EST250 1 x 2 0 litre Everlast stainless steel solar hot water tank with a single 3.6 KW heating element
or
Par /n – EST315 1 x 31 litre Everlast stainless steel solar hot water tank with a single 3.6 KW heating element
or
Par /n – GST160 1 x 160 litre Everlast stainless steel solar hot water tank for Bosch 21e gas boost
or
Par /n – GST250 1 x 2 0 litre Everlast stainless steel solar hot water tank for Bosch 26e gas boost
or
Par /n – GST315 1 x 31 litre Everlast stainless steel solar hot water tank for Bosch 26e gas boost
Par /n – SCU20A Solar Control Kit (assembly), comprising 1 x Solar Control unit, 1 x Solar pump,
1 x ½”F x ½” CTI Conetite union, 4 x screws for attaching to wall
Par /n – SWI00A Solar water Inlet assembly to collectors, 1 x 8 0 kpa Expansion Control Valve, 1 x 1 mm Tee
fitting, 1 x ½”M x ½” CTI Conetight union, 1 x ¾” to 1 mm reducer
Par /n – CWI20A 1 x Cold water inlet assembly (point H), comprising 1 x W63 bent brass fitting, 1 x 20mm-
1 mm Reducer plus 1 x 1 mm copper Tee
Par /n – SWR00A 1 x Solar Collector Outlet assembly (point k), comprising an Air vent, solar collector temperature
receptacle, 1 x 1 mm Kinko nut, 1 x 1 mm olive, 2 x 1 mm Tee fittings, 2 x 1 mm nipples,
1 x ½”M x ½” CTI Conetite union, 1 x 1 mm-10mm bush, 1 x ¾” to 1 mm reducer
Par /n – DUO00A 1 x DuoValve assembly comprising 1 x duo valve, 2 x 1 mm nipples, 1 x W62 straight brass fitting
Par /n – PLV00A 1 x Pressure Limiting Valve 00 kpa assembly, 1 x 1 mm nipple, 1 x W62 straight brass fitting
Par /n – NRV00A 1 x Solar Return Inlet check valve, 1 x 20mm nipple, 1 x 20mm-1 mm nipple, 1 x 1 mm brass
Tee, 1 x 1 mm brass elbow, 1 x W62 straight brass fitting, 1 x 1 mm nipple for W62, 1 x 1 mm
purge valve (point G)
Par /n – SOV00A 1 x Shut-off ball valve assembly comprising 1 x ball valve, 1 x ½”M x 1/2” CTI Conetite union
Par /n – END004 4 x plastic end caps for Roof Frame
Par /n – PTR850 1 x 8 0 kpa Pressure and Temperature Relief valve (point J)
Par /n – BSR00A 1 x ¾ “- ½” reducer, ½ “ nipple, ½” olive, ½ “ Kinko nut, copper sensor receptacle, 1 x Blanking Plug
Par /n – SHW00E 1 x Solar Tank hot water out connection, comprising 1 x 1 mm F/F Brass Elbow, 1 x 20mm-
1 mm Reducer (point F) - Electric Tank
Par /n – SHW00G 1 x Solar Tank hot water out and Gas Booster connection kit, comprising 1 x ¾” nipple and 1 x ¾” W62
1 x ¾”F to ½” Conetite CTI union, 2 x ¾” No 3, 1 x Water Valve, 1 x Gas Valve, 3 x Teflon washers
Par /n – SEC002 1 x solar tank sensor cable,1 x solar collector sensor cable, 1 x test plug, cable ties
Par /n – SRC00A 1 x Solar recycle outlet connector, comprising 1 x W63 bent brass fitting, 1 x 20mm-
1 mm Reducer (point P)
Par /n – TEMP01 1 x Solar Rated Tempering Valve
Par /n – PTFE01 1 x reel of PTFE tape (for 1 or 2 solar collectors)
Par /n – PTFE02 2 x reels of PTFE tape (for 3 solar collectors)
Par /n – BGB21E 1 x Bosch Highflow Gas Boost Heater 21E - (model YE2170RAH - incorporates a Solar Transfer Valve)
Par /n – BGB26E 1 x Bosch Highflow Gas Boost Heater 26E - (model YE2670RAH - incorporates a Solar Transfer Valve)
BGB21E – Bosch Gas Boos Hea er 21E BGB26E – Bosch Gas Boos Hea er 26E
For Gas Boos Hea er Sys ems

8
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
PTFE001 – Thread Tape
SSF001 - S ainless S eel Frame
SSF002 - S ainless S eel Frame
SSF003 - S ainless S eel Frame
PTFE002 – Thread Tape
SRC00A – Solar recycle ou le
Connec or
SOV00A – Shu -off ball valve assembly
PTR850 – Pressure and Tempera ure
Relief Valve (ac ual model may vary)
Note: This item is packed behind the electrical
heater accesspanel In the Everlast Electric
boosted Solar Tanks
END004 – Plas ic End Caps
for Roof Frame
SET348 - 3 x Solar Collec ors
EST315 - Everlas s ainless s eel
315 li re Solar ank
SET161 - 1 x Solar Collec or
SET232 - 2 x Solar Collec ors
SHW00E – Elec ric Boos - Solar Tank Ho Wa er
ou connec or (connec s o Tempering valve)
SHW00G – Gas Boos - Solar Tank Ho Wa er
ou connec or and Gas Boos er connec ion ki
BSR00A – Bo om Sensor Recep acle
and ¾” BSP Blanking Plug
SEC002 – Sensor Cables, Cable Ties
and Tes Plug

9
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
3. Suntrap Solar Hot Water Kit - Parts supplied (cont)
SCU20A - Solar Con rol Ki assembly CWI20A – Cold Wa er Inle assembly, and copper Tee
SWR00A- Solar Collec or ou le assembly
SWI00A Solar Collec or inle assembly including he
Expansion Con rol Valve
NRV00A – Solar Re urn Inle Non-Re urn Valve wi h Purge
Valve assembly (Solar ho wa er in o Solar Tank )
DUO00A DuoValve assembly (ac ual model may vary)
PLV00A – Mains wa er inle Pressure Limi ing Valve
assembly
TEMP01 – Solar Ra ed Tempering Valve
(fi ed o he Ho wa er ou le o he ba hrooms)

4. Schema ic Diagram of he Sun rap Solar Ho Wa er Sys em (Elec ric Boos )
10
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
Schema ic Diagram of he Sun rap Solar Ho Wa er Sys em (Gas Boos )
Solar
Pump
Solar
Control
Unit
Solar
Collector
Solar
Collector
Hot Water Out
to taps
Tank temperature sensor
Pump
Control
Connection
Solar Hot Water Out
Non Return Valve
and Purge Valve
(G)
F
E
J
U
H
Solar
temperature
sensor cable
8 0 kpa Pressure and
Temperature Relief Valve
Solar Tank 00 kpa Pressure Limiting Valve
Air Vent
K LM
Cold Water in
Solar
recycle
Electrical
supply for
heating element
O
Solar Collector outlet connection Solar Collector inlet connection
Solar
Collector
N
Either one, two or three Solar Collectors,
depending on system
Tempering
Valve
DDomestic electrical supply
Expansion Control Valve
DuoValve (on/off and one way)
Tank temp
receptacle
Shut-off ball valve
S
T
C
Use copper Tee
G
Cold Water in
V
Blanking Plug
Solar Collector temp receptacle
P
Solar Hot
water tank
R
Solar Hot
Water tank Solar
Pump
Solar
Control
Unit
Solar
Collector
Solar
Collector
Hot Water Out
to taps
Tank temperature sensor
Pump
Control
Connection
Solar Hot
Water Out
Non Return Valve
and Purge Valve
(G)
F
E
J
G
H
Solar
temperature
sensor cable
8 0 kpa Pressure and
Temperature Relief Valve
Solar Tank 00 kpa Pressure Limiting Valve
Air Vent
K LM
Cold Water in
Electrical
supply
Cold
Water in
Solar
heating
recycle
Solar Collector outlet connection Solar Collector inlet connection
Solar
Collector
N
Either one, two or three Solar Collectors,
depending on system
Tank temp receptacle
Ou le B
Inle A
Bosch Gas Boos er (21E/26E)
Solar Transfer
Valve (STV)
Tempering Valve
50
50
Bolt Gas Booster to Tank if possible
P
Ou le C
D
Solar recycle
Expansion Control Valve
DuoValve (on/off and one way)
Shut-off ball valve
C
T
Use copper Tee
S
U
V
Blanking
Plug
Solar Collector temp receptacle
R
Gas Booster
Water In
Gas Booster
Hot Water Out

11
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
. The Suntrap Solar Control Kit (Electric)
•The Solar Con rol Ki con ains he following
i ems:
• 1. The Solar Pump
• 2. Shut-off ball valve (P/n SOV00A)
• 3. The Solar Controller Unit
• Two water pipe connections are made to the
Suntrap Solar Control Kit. Both water pipe
connections are made via 1 mm Conetite unions.
• Point D is from the cold water inlet to the bottom of
the solar tank.
• Point E is the pumped outlet to the solar collector
• There are 2 electrical plug-in connections
associated with the Suntrap Solar Control Kit:
• The solar pump is plugged into the Pump socket
underneath the Solar Control Unit
• The complete Solar Control Kit is plugged into a
standard 10 amp domestic power socket
• There are 2 temperature sensor cables which need
to be plugged into the underside of the Suntrap
Solar Control Unit: these are the Tank sensor (from
Point H) and the Collector sensor (from Point K)
cables
E
1
2
3
D
The Suntrap Solar Control Kit (Gas)
•The Gas Boos Solar Con rol Ki con ains he
following i ems:
• 1. The Solar Pump
• 2. The Solar Controller Unit
• 3. The ½”F x ½” Conetite CTI union
• There are two water pipe connections made to the
Suntrap Solar Control Kit and shut-off ball valve. All
water pipe connections are made via 1 mm
Conetight unions.
• Cold water enters from the mains water supply
through the DuoValve and Pressure Limiting Valve
(point C)
• Cold water enters the bottom of the solar tank (Point
H)
• Point D is the inlet to the solar pump from the Tank
Solar Re-cycle (Point P)
• Point E is the pumped outlet to the solar collectors
E
D
Bottom connections to Gas Tank
Top connections to Gas Tank
P
P
JF
F
J
HH
G
G
To Solar Collectors
(via pump)
Cold Water in
From solar Collectors
8 0 kpa PTR Valve
connection
Solar Hot Water out
Cold Water in
Solar
Hot
Water
Out to
PTR Valve
C
Solar
Transfer
Valve,
Gas boost
Heater and
Tempering
Valve to
Hot Water
taps
U
Tank temp
receptacle
Tank temp
receptacle
U

12
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
6. Completed installation views of assembled parts
Solar Con rol Ki – solar pump and Solar Con rol Uni
Also shows shu -off ball valve fi ed P/n SOV00A
Cold Wa er Inle - and Tank empera ure sensor
recep acle (Poin s H and U)
Solar collec or ou le assembly consis ing of he Air Ven
assembly, solar collec or empera ure sensor recep acle and
a ½”M x ½” CTI Cone i e union o join o 15 mm pipe (Poin K)
Solar collec or inle assembly, including he Expansion
Con rol Valve and he ½”M x ½” CTI Cone i e
union o join o 15 mm pipe (Poin L)
Part/n SCU20A and SOV00A Part/n CWI20A (H) and BSR00A (U)
Part/n SWR00A
L
Part/n SWI00A
K
U
H
LK
850kpa Pressure and Tempera ure Relief valve (poin J)
Solar re urn inle - non-re urn valve wi h he purge
valve assembly (poin G)
Showing bo h he Pressure and Tempera ure Relief valve
(Poin J) and solar ho wa er ou connec ions (poin s F, S)
(Elec ric Boos ) (Poin T is cold wa er in o Tempering Valve)
Coupling be ween he solar collec ors (Poin s M and N)
(No e: ac ual model may vary)
Part/n FCS002, FCS003 Part/n PTR8 0
Part/n NRV00A Part/n SHW00E (Point F),TEMP01, PTR8 0 and Blanking Plug (V)
J
Please no e ha on Gas Tanks he connec ions
F and J are swapped over)
M and N
S
J
F
T
V
G
R

13
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
Sensor Cables, Cable Ties and Tes PlugSolar Con rol Uni indica or panel
Underside of he Solar Con rol Uni showing
Plug and Sensor connec ion poin s
Underside of Solar Con rol Uni showing empera ure
sensor plug-in posi ions
6. Completed views of assembled parts (cont)
7. Connections to the Suntrap Solar Collectors
• Using 40mm thickness insulation, a 1 mm
copper pipe from the Solar control Kit (point E)
connects to a ½” M x ½” CTI Conetite union
threaded on to a Tee. Connect the other side of
the Tee to the inlet side of the solar connectors
(point L) through the ¾” F to 1 mm brass
adapter. (use thread tape)
• Screw the Expansion Control Valve onto the
Tee using the 1 mm nipple supplied (use
thread tape)
• – The solar collectors are connected ‘in series’
using brass connectors
• Using 40mm thickness insulation, a 1 mm
copper pipe from the middle pipe connection on
the Solar Tank (point G) is connected to the solar
collector outlet (Point K)
• The Air Vent and Solar temperature ‘collector’
sensor assembly is connected into the solar
collector outlet (Point K)
• The Air Vent is screwed into the brass Tee fitting
using the 1 mm -10mm brass bush as shown
(mount vertically)
• The ½”M x ½” CTI Conetite union is used to
connect to the solar water return outlet pipe
• Use thread tape on the solar collector threaded
connection
• The ¾” F to 1 mm brass reducer connects the
Air Vent assembly to the collector
L
K

14
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
7. Connections to the Suntrap Solar Collectors (cont)
• The top picture shows the Solar Collector
inlet connection (with the Expansion Control
Valve) from the solar pump to the solar
collectors using the connectors supplied
(Point L). Use the ¾”F to 1 mm brass
reducer, the 1 mm Brass Tee and ½”M x ½”
Conetite CTI union to connect to the Solar
inlet pipe. Use the 1 mm nipple to connect
the Expansion Control Valve.
• Use thread tape on the solar collector
threaded connection.
• (Part/n SWI00A)
Part/n SWI00A
Part/n FCS002, FCS003
The lower picture shows the connection between
the solar panels (in ‘series’) using the
supplied connectors (Point M).
• The 2 connectors used are ¾”F x ¾”
Conetite CTI unions fitted onto an 82mm
length x 20mm dia copper pipe.
• Use thread tape on the solar collector
threaded connections
(Note: This part is not supplied with a 1 x
solar collector system.)
M and N
L
8. Connections to the top of the Solar Hot Water Tank
• This picture shows the connection to the top
pipe connection on the solar tank (Point F)
which is the Hot water outlet to the
Tempering Valve
• The Tempering Valve (Point S) – Hot water
out to hot taps
• The cold water input to the Tempering Valve
enters at (Point T). This connection to the
cold water supply to be made after the cold
water has flowed through the DuoValve and
00 kpa pressure limiting valve
• The 8 0kpa Pressure and Temperature
Relief valve (fitted at Point J) – is supplied
as part of the kit from Suntrap.
• Fit the Blanking Plug to point V (part of
P/N BSR00A) - this port is not used
• The bottom picture shows the Solar Hot
water out connector and the Gas Booster
connection kit
Please no e ha on Gas Tanks hese connec ions
are swapped over (Elec ric boos ank shown)
SHW00G – Solar ho wa er ou connec or and
Gas Boos er connec ion ki
F
S
T
J
F
V
SR

1
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
9. Connections to the middle and bottom of the Solar Tank
• The middle Solar tank connection (Point G)
Solar hot water in - has a non-return valve fitted.
Connection is made via 1 mm W62 brass fitting.
• Please note the purge valve which must be
used to remove all the air from the solar
collectors and the system during the initial fill
with water. Failure to bleed air from this point
will prevent the solar return water from operating
the non return valve. All air must be expelled at
this point and only water be present, otherwise
the solar water will not circulate between the
solar collectors and the tank. WARNING –
wa er expelled from his poin can be
ex remely ho and precau ions mus be
aken.
• The Solar tank temperature receptacle (Point U)
is where the sensor cable from the Solar Control
unit (front ‘TANK’ socket marked blue) is placed.
Push the sensor head in as far as it will go. This
is the point where the tank temperature is
measured .
• The mains cold water in at the bottom of the
Solar tank connection (H) is made by screwing
the complete assembly into the tank.
Connection to the pipe is made via the W63
bent brass fitting.
• The solar recycle connection (solar flow) is
connected from Point P on the tank to the inlet
to the solar pump (Point D).
G
U
H
P
U
10. The completed Solar Hot Water Tank assembly
• The Tank and Solar control kit must be
positioned close together
• The Solar tank must sit on firm and level ground
• If the solar tank is to be installed inside a
building, then solar tank must sit within a ‘safe
tray’ which meets the drainage requirements of
AS/NZS 3 00.4
Electric Boost:
Solar hot water is piped directly to the domestic
hot water taps (via a Tempering valve). An
electrical connection must be made from the
Solar Hot Water tank to a dedicated electrical
heater supply to provide a ‘boost’ at times when
necessary. (connected to a dedicated electrical
supply for this purpose - (point O)
Electrical cable entry is via an entry provided
to the side of the access cover
Gas Boost:
A separate Gas Boost heater must be installed
on the hot water outlet from the solar tank. For
maximum operational efficiency the Gas Boost
heater (incorporating the Solar Transfer Valve
(STV) should be mounted as close as possible to
the solar tank to minimise the effect of ‘dead leg’
water (water that goes cold in the pipes between
the Tank and Gas Boost heater) from
unnecessarily activating the Gas boost heater.
A Tempering valve is also required to be fitted,
prior to the hot water going to the domestic hot
water taps.
Electrical connection for Boost (Point O)
Cable
Entry
point
Part/n EST31
Safe
Tray

16
12. Instructions for assembling and fitting the Solar collectors
• Your solar collectors will arrive with the evacuated glass tubes installed. These evacuated glass tubes must be
handled very carefully – Please note that these glass tubes never come into contact with the solar hot water, so if
they ever got broken during the operational life of the solar hot water system, no solar hot water will ever get lost.
They are easy to replace in-situ and do not require the system to be drained. This is because the Suntrap Solar
Hot water system uses U-Tube solar collector technology which fully contains all the solar water within high
pressure copper pipes which run inside the evacuated glass tubes.
As can be seen from the following pictures, the evacuated glass tubes slide into the
collector manifold and are retained by plastic shrouds at the opposite end.
16 U-tubes make up 1 x Solar Collector
2 x Solar collectors are shown below
Part/n SET232
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
11. Check list immediately prior to commissioning System
Pre-check list before starting to commission system:
Do not attempt Solar collector installation on a hot day – the Solar collectors and
fittings will be too hot to touch
• Turn off mains water supply valve
• Make sure all connections are tightened
• Make sure all fittings are securely tightened
• Ensure Air vent valve has been opened at least 1 turn (and leave open)
• Understand the importance of correctly purging the system – use of the purge valve at
point G (and the Test plug) – if air is left in the system, this valve will not open and
recirculation will not take place: the Solar collectors and pipe work will pressurise, the
pump will be put under strain and damage could result. WARNING – the water
expelled from point G can be extremely hot and precautions must be taken.
• Ensure that the temperature sensors are correctly placed and secure – again, if these
are not sensing the correct temperatures, the Solar controller will not operate correctly,
which could result in the PTR valve on the tank operating prematurely, and wasting
water. (incorrect temperature detected and solar tank water gets too warm)
• Turn on mains water supply valve, Turn on Duo Valve
• Turn on ball valve at point C (handle in-line with pipe)
• Check diagram below – connections and components to be installed in the order
shown
• OK to start commissioning system
Cold water in
DuoValve
00kpa Pressure Limiting Valve
To Tempering valve (point T)
Tank cold water in
(point H)
Mains water supply valve
Use copper Tee

17
Removing the evacuated glass tubes from the Collector frame
Note the groove on the
front face which is
located into the frame
Push the rear of the evacuated glass
tube retainer upwards
Gently pull the retainer
off the evacuated glass tube
Place the evacuated glass tube retainer to one side
and gently pull the evacuated glass tube out of the
Manifold and over the copper U-Tube.
The evacuated glass tube will slide out of the manifold with the rubber
grommet, When sliding the evacuated glass tube from the manifold
and over the copper U-tube, ensure it is kept in-line with the aluminium
U-Tube copper pipe retainers, so nothing is damaged.
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
12. Instructions for assembling and fitting the Solar Collectors (cont)
• The solar collector frames are mounted on a Roof Frame which must be assembled using the 4 x lengths of
square section stainless steel, brackets and screws supplied. Tap in the 4 x plastic end caps into the cut-off ends
of the frame square sections
• 4 x ‘L’ shaped brackets attach each collector frame to the Roof Frame
• With all the evacuated glass tubes removed (see below) from the collector frames, take the collector frame(s)
to the roof
• The Roof Frame is then taken to the roof and placed in its final position.
• The collector frame(s) must then be mounted to the frame using collector mounting brackets and nuts and washers and
screws. Note there are left-hand and right-hand brackets supplied.
• The thinnest edge of each mounting bracket (from slot to edge) must be positioned to the outside of the frame
• Finally (see the next pages) , the stainless steel straps must be positioned along the frame (two at the top and two at
the bottom to line up with the roof rafters under the roof tiles on which to screw the frame (assuming a tiled roof)
on each stainless steel strap, screw one screw into the frame and the other 2 x screws into a roof rafter. Repeat
for each stainless steel strap
• Take the evacuated glass tubes to the roof and insert all evacuated glass tubes into the solar collector frames
Thin
edge

18
12. Instructions for assembling and fitting the Solar Collectors (cont).
Refitting the Evacuated Glass Tubes.
Slide the evacuated glass tubes over the U-Tube copper pipes and aluminium retainers and into the manifold.
Gently ease the grommet into position for a flush seal.
The stainless steel Roof Frame and the stainless steel straps are taken to the roof with no bends in them. When the position of
the Roof Frame has been established, slide a tile up and locate a rafter. Using 2 x of the long roof screws, screw the strap into
position on the rafter so that there will be a sufficient length exposed beyond the normal position of the tile to attach to the roof
frame. Slide the tile back into its normal position. Re-position the Roof Frame, then bend the strap around the Roof Frame to
secure. Repeat this for the other 3 x stainless steel straps.
When all the stainless steel straps have been bent around the Roof Frame and the Roof Frame is in its final position, drill through
both the straps and frame with a 3 mm drill, and screw together.
To refit the evacuated glass tubes into the
Collectors - Reverse the instructions for
removing the evacuated glass tubes from
the collector frame (see previous page).
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
13. Completing the Installation
• Please refer to Schematic Diagram (Section 4) for all reference points:
•Please no e ha he blue and red do s on each end on he collec or have no significance – flow and re urn can be in
ei her direc ion.
• For the Solar Tank Installation - Please refer to the Everlast Owners Manual and Installation Guide.
• Pipe insulation - Use 40mm hickness ISOpipe insulation material on the solar inlet and solar outlet pipes all the way from the
solar hot water tank to the solar collectors and back to the solar hot water tank. For Gas Boosted systems, use Armaflex
material 32mm thickness insulation between the Solar Preheat Tank and the Gas Booster.
• Position the Solar Hot Water tank on firm and level ground near an electrical supply.
• Screw the Shut-off valve to the outlet of the solar pump (Point E). Fit the ½”M x ½” Contite CTI union to the Shut-off valve.
• Position the Solar Control Kit on a wall adjacent to the Solar Hot Water Tank approx 120cm from the ground and within the
‘Tank’ sensor cable length.
• Remove all evacuated glass tubes from the collector frame(s) and put to one side (see section 12).
• Identify the final position of the solar collectors on the roof.
• Assemble the Roof Frame and take it to the roof (see section 12).
• Attach the assembled Roof Frame to the roof using the 4 x stainless steel straps (see section 12)
If installing the Roof Frame on colorbond (Metal) material, use rubber insula ing s rip between the Roof Frame and the Roof
• Take the collector frames(s) to the roof (suppor he U ubes and aluminium fins
•when moving he bare collec or frames. Keep all he U ubes in-line and a
90 degrees o he manifold a all imes) see pic ure – use a piece of wood
and some ape as shown - and attach these collector frames to the Roof Frame
using the brackets and nuts and bolts and screws supplied (see section 12).
• Take the evacuated glass tubes to the roof.
• Re-fit all the glass evacuated glass tubes to the collector frame(s) – (see section 12).
• Fit the Air Vent assembly to the solar collector outlet connection on the Solar Collector using thread tape (Point K). Use two
spanners to prevent twisting the manifold.Ensure ha he air bleed valve is unscrewed - open (see section 7).
• Screw the Air Vent into the Air Vent Assembly using thread tape.
• Fit the 8 0 kpa Pressure and Temperature Relief valve assembly on the Solar Hot Water tank, using thread tape (Point J)
(see section 8).
• Fit the 00 kpa Pressure limiting valve assembly on the Solar Hot Water tank, using thread tape
• (Point H)(see section 9).
• Fit the non-return valve assembly and the purge valve on the solar input on the Solar Hot Water Tank, using thread tape
(Point G) (see section 9).

19
Copyright © 2009 Suntrap Pty Ltd All rights reserved ABN 87 117 0 2 8 6
• Ensure that the DuoValve is closed (on the mains water-in pipe)
• Turn on the main water supply.
• Check for water leaks along this mains ‘cold water in’ pipe.
• Turn on a hot water tap fed from the Solar tank (this assists with the removal of air from the system
during initial fill.
• Open the DuoValve on the Mains water-in pipe to allow water to enter the Solar tank.
•Open he purge valve on he Solar Re urn Inle connec ion o he ank (poin G) (very important to
prevent an air lock on initial fill). Warning – the water expelled from point G can be very hot and
precautions must be taken. This is best carried out when the Solar Collectors are cool.
• While filling the Solar Tank with water - hold open the 8 0kpa Pressure and Temperature valve
(Point J) – this also assists with the removal of air during initial fill.
• Also while filling the Solar Tank with water - watch for water to be expelled at the purge valve on the Solar
Return Inlet connection to the Tank point (point G) (water will have now partially filled the on-roof solar
collectors and pipes) –air will ‘hiss’ until water is expelled). When only water flows, close the purge valve.
• When water is expelled from the P and T Relief valve (Point J), let the valve close.
• Allow water to continue to enter the Solar Tank. Water will begin to come out of the hot water tap
previously left open. When there is a steady flow of water, turn off all hot taps. Check for any water leaks.
• Plug the solar pump into the ‘Pump’ socket on the underside of the Solar Control Unit.
• Plug the Solar Control Unit into a suitable electricity supply, and switch on the Solar Control Unit. The power
light should illuminate. Unplug the Collector Sensor cable (marked with a Red label) from the Solar Controller.
Plug the ‘Test Plug’ (supplied with the Solar Controller) into the Collector sensor input (marked with a Red label)
on the underside of the Solar controller and the pump should start. Open the purge valve and run the pump
for 10 minutes to ensure all the air is excluded from the solar collectors. Close the purge valve. Remove the
key to a safe place. Remove the ‘Test Plug’ to a safe place. Replug the collector sensor lead into the Controller.
• Ensure that Silicone seal is around the tank sensor cable, only at the entry point to the temperature receptacle
(for easy sensor removal if necessary).
• When the Solar Collector temperature sensor detects a temperature greater than 9 degrees above the tank
water temperature, or 1 degree centigrade, the solar pump will run and the ‘pump’ indicator will illuminate.
• Check for any leaks and take corrective action.
• Look forward to a very efficient and cost effective hot water delivery system, powered by the sun.
14. Priming and filling the system
• Fit the Solar hot water outlet connector to the Solar Tank, using thread tape (Point H).
• Connect the DuoValve (P/N DUO00A) and the water Pressure Limiting Valve (P/N PLV00A) together,
ensuring that the arrows on the valves are towards tank (point C), using thread tape. Run a length of
1 mm pipe from the Pressure Limiting Valve to the tank. (Use the copper 1 mm Tee to connect to
Tempering valve (Point T), Connect the Solar recycle (point P) on the tank to the solar pump inlet (Point D).
Run a length of 1 mm pipe from the Duo Valve and connect back to the ‘mains cold water in’ connection
Point C).
• Connect the Solar Collectors together using the connectors supplied. Use thread tape on the solar
collector threaded connections (Points M and or N). Use two spanners to prevent twisting the manifold.
• Run a length of 1 mm pipe and connect from the Shut-off ball valve (Solar Pump outlet connection – point E)
to the ½”M x ½” CTI Conetite union on the 1 mm Brass Tee on the Solar Collector inlet connector.
Connect the 20mm – 1 mm adapter to the collector and screw to the brass Tee fitting. Fit the Expansion
Control Valve. Use thread tape on all threaded connections (Points E to L). (use two spanners
to prevent twisting the manifold when tightening the 20mm-15mm adapter to the collector).
• Run a length of 1 mm pipe and connect from the Solar Collector outlet assembly – from the ½”M x ½” Conetite
CTI union to the W62 straight brass fitting on the Solar input on the Solar Hot Water, tank (Points K to G).
•Electric Boost - Connect the Brass Elbow fitting to the ‘Solar Hot water out’ (Point F) and then to the Tempering Valve.
•Gas Boost – Fit the W62 and nipple to the tank (Point F), run a 20mm pipe to the Water Inlet connection on the Gas
Booster, then connect from the Hot Water outlet on the Gas Booster with 1 mm pipe to the Tempering Valve (Point R)
• Fit the tank temperature sensor receptacle (P/N BSR00A) into point U.
• Screw the 3/4”BSP Blanking Plug into (Point V) on the tank
• Connect a cold water feed (from the Tee in the cold water-in pipe) to the Tempering Valve (Point T)
• From the ‘outlet’ connection of the Tempering Valve (Point S) run a 1 mm copper pipe to the Hot
water out (Point S to hot water taps)
• Place the 2 sensor probes into their respective ‘blind’ receptacles – ‘cold water
in’- ‘Tank’ temperature (Point U) and the ‘Solar collector outlet’ – ‘Collector’ temperature (Point K).
• Silicone seal around the sensor cables, only at the entry point to the temperature receptacles.
Plug the other ends of the sensor cables into their respective marked positions on the underside of
the Solar Control Unit.
• Secure any loose cables with cable ties.
• For all Gas Boosted Heater system installations – Please see diagram in Section 4, and notes in Section 10
Gas connection must be carried by a qualified tradesperson – refer to the Gas Boost heater manufacturers instructions.
• Check all fittings and tighten as necessary.
13. Completing the Installation (cont)