Sun Power SP250U18 User manual

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Sunpower
Operation / Installation manual
Version 1.1 Date: 18 Sep 2016
This manual applies to model:
SP250H25, SP315H30, SP400H40, SP500H50
Foreword
This handbook is a technical manual with instructions for the
SUNPOWER spilt system high pressure solar water heater's use.
Also contains installation instructions. Please read this handbook in
detail, before installing the SUNPOWER system. All system must
follow installation instructions strictly.
The appliance must be installed, commissioned and serviced by an
authorized person (licensed plumber) in accordance with the
requirements of AS/NZS 3500.4 or in New Zealand, NZBC G12.”
All Sunpower systems have the Australian watermark standard, and
ensure you are getting Australian quality.
Sunpower systems are also accredited with various certificates (like
EN12975 and Solar Keymark) These International certification

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organizations provide customers with trust and confidence in
Sunpower products
This is the common-sense warning that we have to include.
NOTE
In order to guarantee that your safety, please note the following
security item, in order to avoid causes the hot water system's damage
Before using the hot water, please test the water, in the
water bowl. Use the hot water and cold water through the
mixing taps, to prevent against scalds!
All systems must be connected, with the safe ground wire
device! (earthed)
When touching the auxiliary electric heating, you must
make certain that the power is off.
The power supply must be off when there is no water in
the tank.
The T/P valve drain pipe should be located in a safe area,
or joined to a closed drain. When the T/P valve opens the
discharged water temperature is very high. If not done
safely, scalding could result.
The installed power supply outlet should have a cover over
to stop water entry. Indoor / outdoor types
We suggest that every two month you open the handle of
the T/P operating valve (slowly). If the valve does not
open, perforates the air vent with a needle or thin iron
wire.
15A ～250V
Use only Australian certified electrical power outlets.
The current capacity has to be bigger than 15A!

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Product outline and how the Sunpower system works.
The collectors are generally installed on the roof, and the water tank on the
ground. Sunlight is collected by the evacuated tubes, and converted to heat.
This in turn heats a “copper heat pipe “inside the evacuated tube. There is a
copper pipette at the top of the tube, which has your tank water circulated
around it. The heat is then transferred to your water.
The electronic control box (supplied) has 3 sensors. One is at the outlet on
the evacuated tube manifold, one is at the bottom of the tank, and the third
is in the middle of the tank. When the control box registers a difference of
10 degrees Celsius between the outlet / bottom sensor, it switches the pump
on (supplied), until there is only 5 degrees difference. Then the pump is
switched off. This cycle repeats until such time as the middle sensor reads
80 degrees Celsius. Then the control box will not allow the pump to switch
on. This not only protects the tank, but ensures no water wastage through
the P T R valve on the tank.
Product characteristic：
Evacuated heat pipes. This means no water in tube, no possibility of scale
build up, and no cracking of the tube due to water expansion
The collector has integration modulation technology (top sensor reads 5
degrees Celsius). This allows the control box to switch the circulating
pump on in severe conditions (frost), circulates the bottom 50 litres of
water in the tank (approx), and ensures that there is no likelihood of
freezing in the copper pipes.

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Sunpower systems have a 3.6 Kw electric heating element in the tank.
These guarantee all weather hot water availability. They are also able to
couple to Natural gas and L P G heaters, as back up heating, instead of
using the electrical element.
All Sunpower tanks are marine grade, and stainless steel.
Product function：
The control box has digital displays for the collector and water tank
temperature
There is an inbuilt power failure automatic memory. This can guarantee
that the control box does not lose
·Automatic electric heating function
·Manual key modulation electric heating
·Fixed time electric heating
·Manual pump circulation
Tank and Collectors composition
Collector: Include evacuated tubes with heat pipe, and heat transfer
aluminum fin.
The water storage tank：Inner tank uses the SUS304-2B food grade
stainless steel plate, using the automatic welding craft processing;
Corrosion-resistance, polyurethane high temperature high insulation
The outer tank uses the color steel plate, has the very good radiation
protection (U/V), and better corrosion resistance.

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Main tech info.
·water tank capacity：250~500L；
·heat pipe or vacuum tube:φ58*1800；
·working pressure：≤0.6MPa；
·controller power：3W；
·The water temperature control within 2℃；
·The circulating pump power≤600W (Wilo pump at 22 W)；
·Working voltage：Exchange 220-240V(50HZ)；
·The electric heating element：≤3600W。

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Environmental request
1、The altitude above sea level does not surpass 3500m;
2、Controller indoor air relative humidity ≤95%;
3、Controller office work temperature - 20℃~60℃;
4、Mains pressure inlet (cold water) ≥0.1MPa；
5、Frost protection：level 2
Product specification series table
Product specification series table
Model
Tank
capac
ity
Solar collector
Heating
elements
power
(KW)
Each solar collector
size
Tank
size（mm)
height*
diameter
Collec
tor
area
（㎡
）
Working
pressure
(MPa)
Length
(mm)
Tube
NO.
（pcs
）
length*width*
height(mm)
SP250U18
250L
1800
18
3.6
1530×1520×1400
540*1800
2.43
0.1~0.6
SP250H20
250L
1800
20
3.6
1530×1680×1400
540*1800
2.71
0.1~0.6
SP315U18
315L
1800
18
3.6
1530×1520×1400
650*1540
2.43
0.1~0.6
SP315H20
300L
1800
20
3.6
1530×1680×1400
650*1540
2.71
0.1~0.6
SP315U25
300L
1800
25
3.6
2270*1120*140
650*1540
3.37
0.1~0.6
SP315H25
300L
1800
25
3.6
1530×2080×1400
650*1540
3.37
0.1~0.6
SP315H30
300L
1800
30
3.6
1530×2480×1400
650*1540
4.05
0.1~0.6
SP400U30
400L
1800
30
3.6
1530×2480×1400
650*1970
4.05
0.1~0.6
SP400H30
400L
1800
30
3.6
1530×2480×1400
650*1970
4.05
0.1~0.6
SP400U36
400L
1800
36
3.6
1530×1520×1400
650*1970
4.86
0.1~0.6
SP400H40
400L
1800
40
3.6
1530×1680×1400
650*1970
5.42
0.1~0.6
SP500U36
500L
1800
36
3.6
1530×1520×1400
700*2020
4.86
0.1~0.6
SP500H40
500L
1800
40
3.6
1530×1680×1400
700*2020
5.42
0.1~0.6

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The system comprises of several different sections.
Heat pipe solar collectors (various sizes, as ordered).
Water tank (various sizes, as ordered).
Solar collector mounting frame and angle stand (stainless steel).
Tubes as ordered (10 or 15 per box).
3 sensor digital control box, with wilo cartridge type pump (22 W).
All fittings as required, including a temperature control valve, pressure
limiting valve, duo valve, 2 x check valves, P T R valve. With smaller
fittings as required. Sunpower “ pre assembles “ the solar return, pump
fittings, wires the control box to the pump, and fits sensors.
Product Installation
The installation of the solar water heater should not compromise the
structural integrity of the building.
Water tank installation
Ensure the ground is smooth and the tank is in a stable position. Please
note. You must leave leeway around the tank, and collectors for installation
access and for any maintenance if required.
Carry on the installment according to the water tank connection chart
Solar collector installation
The collector fixing on the range of roof should more than 1 m from
the edge.
1、Flat type solar collector installation：

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A. X shape parts and back parts connection，（Balcony type
collector、slopping roof type collector no this step）。
B. Front parts, bottom parts and manifold connection
C. Front parts, back parts connection with each other

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2、Balcony type solar collector installation:
Before the user is sure to remember the attention installment, please by
all means must the full confirmation following request: Installs the balcony
(or wall surface, roof) load bearing strength≥80Kg/m2 。
A、Hits the installment hole according to the support reservation hole's
size in the balcony wall surface。
B、Fixes with the plug bolt the support on the wall surface。

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C、If the floor is low may installs the manifold on the stand parts first
and then install the heat pipe, if user’s floor is high is not convenient well
then assembles the vacuum tube heat pipe and manifold, then put the
collector integral hoisting to the user balcony installment
The balcony type collector's assembly reference flat top collector
support assembly step, which except the step for back up supports parts, X
shape parts and other spare part.
3、Slope roofing collector installment
A、With inflates screw bolt and the roofing joint 4 tile hooks, about
each two, the fore-and-aft distance may decides according to the roofing
actual situation and the collector proleg reservation hole size
B、The collector proleg reservation's long round hole and the tile hook
joins with the bolt

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C、The collector's assembly reference flat top collector support
assembly step, which except the step for back up supports parts, X shape
parts and other spare part.
Pipeline's connection (sees system schematic diagram)：
Meets according to the system schematic diagram the pipeline, in cone-
way valve where water inlet. The safety valve installs in the water tank end
specific interface place, the valve end's overflow tube must certainly draw
out to turns on the water safely place. The pipeline must make the heat
preservation, south special area thickness 20mm, the northern area should
thicken the heat preservation (suggestion with the PE material, thickness
30mm), for further frost proof, may install the electricity partner tropics
Care should be taken not to touch the pipe work as it may be HOT!
The pipes between the solar collectors and storage cylinder MUST BE
copper or alternative material pipes that may be supplied by Sunpower.
Plastic pipe is NOT suited to the water temperatures and pressures that may

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occur in the system.
Insulation pipe must comply with the relevant technical standards,
must be black EPP insulation cotton, thickness must be not less than 35
mm, 50 mm is recommended in cold regions; outside must be wrapped in
aluminum foil and UV resistant special tape.
Installment matters attention：
◇Between the collector and the heat preservation water tank circulates
the pipeline to reduce t he knee bend as far as possible; take the shortest
distance as good.
◇The collector and the water tank install the height
difference≤10m。
1. Electric circuit's connection
2. The electric circuit installment should strictly according to the
conventional electrician standard operation
a The power line is three, respectively is L, N and the grounding, uses
1.5mm2 the power line, according to chart connection
b Examination: After the electric circuit meets, before the circular
telegram use, the examination leakage protects the plug “L” and “N” the
resistance should during 30~40 ohms, “L” and the place, “N” and
resistance between the place should above 2,000,000,000,000 ohms
The water quality of most public supplies is suitable for the water heating
system. The water quality from bore wells is generally unsuitable for the
water heating system.

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三、 Operation use
Inspection before use
（１）Just before the use, or stops using for a long time uses again,
deals with the water heater, the power source, the aqueous system, the
pollution discharge system, the safety valve, the discharge valve, and so on
to carry on a time comprehensive inspection
（２）inspection aqueous system whether have the water leakage
place
（３）Inspection pollution discharge and safety valve whether have
the jamming or the safe hidden danger
（４）Before the first use, should clean the water tank, then looked
that in the water tank whether the water-filled (opening hot water export
threshold energy does emit smoothly)
（５）Whether the power source does satisfy the water heater power
request, whether to earth reliably
Operating instructions
◇When fill the water for the first time to open the inlet valve gate at
first, simultaneously turns on the hot water outlet valve is advantageous for
when the water in the water tank to exhaust, otherwise cold water cannot
enter the water tank.
After hot water outlet water leakage, indicated that the inner tank
waters have entered fully, the closure hot water leaves the water valve (inlet
valve not to close)

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◇The connection controller power source, demonstrates the water
tank and the collector water temperature normally
◇The controlled variable supposes the definite opinion controller
operating instructions
◇Make sure to remember that the inlet valve gate should open
throughout
◇Open the hot water valve directly, then uses the hot water.
◇PT valve must be installed, when the system pressure exceeds the
rated pressure, the valve will automatically open, exhaust protection; in
order to avoid scalding, it is recommended to install the exhaust of the
guide tube, but must ensure that the guide tube is unblocked;
◇The lower part of the tank with a sewage outfall, in the case of long-
term no use, it is recommended emptying the water tank, concrete steps are
as follows: First, open the PT valve, then close the influent water, open
sewage outfall, outfall hose can be connected directly to the water
discharged into the sewer;
Freeze protection ◇The system is cycle system without heat exchanger coil,
below 0 ℃area when using this product, you need to make the system with
freezing protection measures: 1, connecting pipes must be installed
insulation pipe, and install heating tapes, 2, in the operation, the controller
must open antifreeze function (according to the controller operating
instructions executed); 3, when there is long time no use system, the water
tank needs emptying;

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The controller operating instructions (see controller instruction
booklet)
System common breakdown and processing
Breakdown phenomenon
causation
Processing method
anhydrous
No water supply or the inlet
valve has not opened
Turn on the inlet valve
The water discharge is
too small
The inlet valve has not operated
the foot, the hydraulic pressure is
low
Operates the full inlet valve,
disposes the pipeline booster pump
When use the water
temperature drops
excessively quickly
Inlet valve opening is oversized
Adjusts the small inlet valve
No demonstration when
start
Mains input plug contact bad
Takes down the mains input plug
inspection, inserts on the tight
electricity
Demonstrated that not
normal (jumps code)
The holding wire has not met
Connects again tightly
Heats up the indicating
lamp to be bright, the
temperature does not rise
The electric heating manages
poorly
Replacement electric heating tube
Cannot stop heating
manual
The current temperature is
smaller than the lower limit or is
at fixed time heats up the
condition
When undetermined past or
temperature increment
Water leakage
Hot and cold control, fitting and
so on place seal bad, feed piping
or other installment revelation
Fastens good seal the inspection
pipeline connection and other
installs
The hot water has the
unusual smell
In cold water the sulfate or
mineral substance content has
had the bacterium
After the draining water, flushes
heating stick the adding water to
carry on the chlorination
The water temperature is
low
Sunshine insufficiency; On the
down-flow pipe installs counter-
the collector surface area has ash
or has covers
Increases the sunshine-hour to
increase the auxiliary energy once
in a while; Installs the circulating
pipe; Elimination collector surface
The hot water quantity is
insufficient
Sunshine insufficiency; Turbid
water; the pipeline is long; Keeps
warm unsatisfactory
Increases the sunshine or adds the
accessory power supply; The inlet
valve opens gently; The reduction
pipeline, increases the heat
preservation thickness as far as
possible

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Matters attention and maintenance
1. The controller and the water pump should install not in the place
which drips wet, and pays attention to, the waterproofing moisture-proof,
dustproof.
2. Make sure that various ties meet, only then electrifies the testing.
3. The controller may 24 hour uninterrupted movement, the power loss
be small, only if the solar-powered water heater does not use, then does not
need to close the power source.
4 Typically, magnesium rod should change every 2 year, first open the
PT valve, then shut off the water, open the drain valve, the water inside the
tank emptied, and to do replacement work (must be handled by the relevant
professional maintenance staff ) once be done, need to check if there is any
leaks.
“WARNING:
IF THE HOT WATER SYSTEM IS NOT USED FOR TWO WEEKS OR MORE, A
QUANTITY OF HIGHLY FLAMMABLE HYDROGEN GAS MAY ACCUMULATE IN THE
WATER HEATER. TO DISSIPATE THIS GAS SAFELY, IT IS RECOMMENDED THAT A HOT
TAP BE TURNED ON FOR SEVERAL MINUTES OR UNTIL DISCHARGE OF GAS CEASES.
USE A SINK, BASIN, OR BATH OUTLET, BUT NOT A DISHWASHER, CLOTHES WASHER,
OR OTHER APPLIANCE. DURING THIS PROCEDURE, THERE MUST BE NO SMOKING,
OPEN FLAME, OR ANY ELECTRICAL APPLIANCE OPERATING NEARBY. IF HYDROGEN
IS DISCHARGED THROUGH THE TAP, IT WILL PROBABLY MAKE AN UNUSUAL SOUND
AS WITH AIR ESCAPING.“
* Additional instruction *
This product like has the modification not in addition to give the
explanation

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This is a ¾ (19 mm) to ½ (13 mm) reducing elbow
for the cold water inlet to the tank. We install this
vertically up as pictured.
Hot water outlet from the tank installed
vertically down. We run copper pipe between the
cold inlets to the hot outlet. A copper T is
installed for the mains cold water line to join into
this copper pipe. It also allows flexibility in
height, and angle for existing mains cold water
lines. N.B. ensure the copper T is located beneath
the Tempering valve, which is also installed on
the copper pipe.
Self explanatory with a ½ copper pipe compression
fitting.
Installed horizontally facing towards the rear of
the tank. This is for ½ copper pipes to lead to the
bottom of the pump.

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The solar return is pre assembled, except for the
top elbow.
This allows flexibility in pipe location from the
collector. The silver stop valve is to “bleed“air
from the collectors when commissioning. The
fitting with the orange band is a high temperature
check valve, and stops water flowing back to the
collectors. Therefore isolating the collectors on the
solar return if required.
The collectors have a simple ½ inch
compression olive / nut for the solar flow, and
return.
Same as the hot water outlet fitting.
The system has been designed so all fittings to
the tank are on the L H S from the front.
It can take a minimum of 150 mm extra width if
required, with all the copper pipes / sensor being
able to be joined inside this area.
It is recommended that the fittings are located in
the 9 O,Clock position for ease of installation,
and maintenance.
The front of the tank is 6, the rear is 12, and
the R H S is the 3 O,Clock position
Tempering Valve
Pum
p

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The control box is pre wired for 240 volt power,
and directing power to the pump.
From the L H S. Power in with brown L (positive),
blue N (negative), and green/yellow as the earth.
Next is the power to the pump (same colour for L,
N, and the earth. T1 is the sensor to the collector
outlet. T2 is the sensor to the bottom of the tank,
and T3 is to the middle of the tank.
Please refer to the supplied manual for the control
box. This control box can be located away from the
tank area if desired. Alls that needs to be done is to
extend the length of the power to the pump, and T2
/ T3 sesor cables.
Please ensure that same colors are joined when
extending. T1 still goes direct to the control box
from the collector.
This is the wiring sequence for the power from
the control box to the pump. L, N, and E.
Sunpower pre assembles the pump fittings.
Below the pump we have a silver stop valve
(same as solar return).Above the pump we have a
high temperature check valve (same as solar
return). This isolates the pump, and also isolates
the collectors on the solar flow if required.
Please ensure the power to the pump is
switched off, when isolating the collectors.