Suntrap ST-250-32, ST-315-48, ST-160-16, ST-160LPG21-16, ST-250NG26-32 Installation Instructions And Owner's Manual

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Solar Hot Water

Installation Instructions

and Owners Manual

AS 2712 Lic 21687 SAI Global

WMKA Lic 21688 SAI Global

This Manual Covers 10 system models:

Electric Boost 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 2158

Tel: 02 9651 2866

Gas Boost 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/Installers – Please read this Manual before attempting the installation of the Suntrap Solar Hot Water System

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

5 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

15 Specifications of the Suntrap Evacuated U Tube Solar Collector SLU-1500/16

16 Warranty and Refund Policy

AS/NZS 4234:2007 Climatic Zones

Used in determining the Renewable Energy Certificates across Australia

1. Renewable Energy Certificates

Calculated Renewable Energy for Suntrap Pty Solar Hot water Products

The following table presents the calculated RECS and annual energy saving for the different Suntrap solar configurations using SLU-1500/16 type evacuated tube collectors

Configuration

Annual Energy Saving (%)

10 Year Renewable Energy Certificate Allocation

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

RENEWABLE ENERGY CERTIFICATES

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 waterin to the DuoValve (point C) and close the Shut-off ball valve (point E) 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 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).

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

160 litre 1140mm(h) x 580mm dia. 250 litre 1620mm(h) x 580mm dia. 315 litre 1980mm(h) x 580mm dia.

Solar collector 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)

Note: All installations must be carried out by authorised plumbers or other authorised persons.

Installer - Please familiarise yourself with all the diagrams and pictures before starting to connect the system together. Installation instructions begin at section 10. Some diagrams/pictures are representative only and some pictures are shown before pipe insulation has been fitted for clarity. To comply with AS2712 certification, the plumbing between the solar hot water tank and the solar collectors must be installed using 12mm internal pipe diameter with insulation thickness of 40mm on the inlet pipe and 12mm internal pipe diameter with insulation thickness of 40mm on the outlet pipe, both pipes using insulation material to ISOpipe insulation standards. For Gas Boosted systems the pipe between the Solar preheat tank and Gas Booster must use Armaflex 32mm thickness insulation.

2. About your Suntrap Solar Hot Water System

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. 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, 250 or 315 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.)

Temperature adjustment

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 850 Valve) which must not be tampered with.

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

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.

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 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 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.

Caring for your system

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 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 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 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 315 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.

Mains water 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 500 kpa and must never be changed for a higher rating.

Installation of the Solar Hot Water Tank and Solar Collectors:

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 Suntrap Solar Hot Water Kits:

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 Suntrap Kits as follows:

(Please note that there are 16 glass evacuated tubes per solar collector.)

Roof space required for Solar collectors:

1 x solar collector 1.2 meters wide x 1.8 meters high 2 x solar collectors 2.4 meters wide x 1.8 meters high 3 x solar collectors 3.6 meters wide x 1.8 meters high

Electric Boost Models: ST-160-16: 160 litre solar hot water tank with 1 solar collector and electric boost -

1140mm (h) x 580mm (dia)

ST-250-32: 250 litre solar hot water tank with 2 solar collectors and electric boost-

1620mm (h) x 580mm (dia)

ST-315-32: 315 litre solar hot water tank with 2 solar collectors and electric boost-

1980mm (h) x 580mm (dia)

ST-250-48: 250 litre solar hot water tank with 3 solar collectors and electric boost-

1620mm (h) x 580mm (dia)

ST-315-48: 315 litre solar hot water tank with 3 solar collectors and electric boost-

1980mm (h) x 580mm (dia)

Gas Boost Models: ST-160NG21-16 / ST-160LPG21-16: 160 litre solar hot water tank with 1 solar collector and gas boost -

1140mm (h) x 580mm (dia)

ST-250NG26-32 / ST-250LPG26-32: 250 litre solar hot water tank with 2 solar collectors and gas boost-

1620mm (h) x 580mm (dia)

ST-315NG26-32 / ST-315LPG26-32: 315 litre solar hot water tank with 2 solar collectors and gas boost-

1980mm (h) x 580mm (dia)

ST-250NG26-48 / ST-250LPG26-48: 250 litre solar hot water tank with 3 solar collectors and gas boost-

1620mm (h) x 580mm (dia)

ST-315NG26-48 / ST-315LPG26-48: 315 litre solar hot water tank with 3 solar collectors and gas boost-

1980mm (h) x 580mm (dia)

For 1 x solar collector (ST-160-16: ST-160NG21-16 / ST-160LPG21-16)

Part/n – SET116 1 x complete Suntrap evacuated tube Solar Collector with 16 x evacuated glass tubes Part/n – SSF001 4 x square sections of stainless steel for Roof Frame (top, bottom and 2 sides)

Part/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

For 2 x solar collectors (ST-250-32: ST-315-32: ST-250NG26-32 / ST- 250LPG26-32: ST-315NG26-32 / ST-315LPG26-35)

Part/n – SET232 2 x complete Suntrap evacuated tube Solar Collectors, each with 16 x evacuated glass tubes Part/n – SSF002 4 x square sections of stainless steel for Roof Frame (top, bottom and 2 sides)

Part/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.

Part/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 components used to connect 2 x Solar Collectors together

For 3 x solar collectors (ST-250-48: ST-315-48: ST-250NG26-48 / ST-250LPG26-48: ST-315NG26-48 / ST-315LPG26-48)

Part/n – SET348 3 x complete Suntrap evacuated tube Solar Collectors, each with 16 x evacuated glass tubes Part/n – SSF003 4 x square sections of stainless steel for Roof Frame (top, bottom and 2 sides)

Part/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.

Part/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 components used to Connect the 3 x Solar Collectors together

+ 15 hidden pages

Suntrap ST-250-32, ST-315-48, ST-160-16, ST-160LPG21-16, ST-250NG26-32 Installation Instructions And Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual