SunMaxx Solar ThermoPower-VTS15-HP Series User manual

SunMaxx Solar LLC
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Manual of Pressurized Solar Water Heater
This manual applies to Models ThermoPower-VTS15-HP-G, ThermoPower-VTS30-HP-G,
ThermoPower-VTS15-HP-E, and ThermoPower-VTS30-HP-E, ThermoPower-VTS15-HP-
TG, ThermoPower-VTS30-HP-TG, ThermoPower-VTS15-HP-TE, ThermoPower-VTS30-
HP-TE.
“The solar energy system described by this manual, when properly installed and maintained, meets
the minimum standards established by the SRCC. This certification does not imply endorsement or
warranty of this product by SRCC.”
The supplier’s name: SunMaxx Solar LLC

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Address: 2917 State Highway 7, Bainbridge, NY 13733
Contents
IMPORTANT INFORMATION AND WARNINGS ........................................................................3
SOLAR WATER HEATER PACK AND TRANSPORT ..................................................................4
1. Features of pressurized solar water heater ....................................................................................5
2. Structure of solar water heater ......................................................................................................6
3. Working principle..........................................................................................................................7
3.1 Principle of vacuum tube ....................................................................................................7
3.2 Working principle of solar water heater ..............................................................................7
4. Technical data and product description .................................................................................9
4.1 Technical data......................................................................................................................9
4.2 System Tolerance Information ............................................................................................9
4.3 System start-up procedures ...............................................................................................10
4.4 System pipe anti-freezing protections...............................................................................10
4.5 Specific notices .................................................................................................................10
5. Installation of solar water heater.................................................................................................12
5.1. Frame installation drawing...............................................................................................12
5.2 Installation of frame ..........................................................................................................13
5.3 Installation of the tank.......................................................................................................14
5.4 Installation of the heat pipe and vacuum tubes .................................................................14
5.5 Solar water heater installation and attention .....................................................................15
6. Pipeline installation.....................................................................................................................18
6.1 Plumbing system schematic map ......................................................................................18
6.2 Plumbing connections .......................................................................................................23
6.3 Pipe Insulation...................................................................................................................27
7. Commissioning the system .........................................................................................................30
8. Troubleshooting ..........................................................................................................................31
9. Maintenance requirements ..........................................................................................................32
9.1. Cleaning ...........................................................................................................................32
9.2. Leaves ..............................................................................................................................32
9.3. Broken tubes ....................................................................................................................32
10. Special conditional operation....................................................................................................33
11. Other important information .....................................................................................................34
12. Warranty Card ...........................................................................................................................34
For your record: ..............................................................................................................................35
ANNEX 1.Components List..........................................................................................................36
ANNEX 2 Notice Label..................................................................................................................38

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IMPORTANT INFORMATION AND WARNINGS
Safety & Regulatory information
DO NOT operate this system before reading the manufacturer’s instructions.
This appliance must be installed, commissioned and serviced by an authorized person
in accordance with all applicable local rules and regulations.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety.
For safety, this appliance must be installed, operated and maintained in accordance with
the manufacturer’s instructions.
Children should be supervised to ensure they DO NOT play with the appliance.
In order to prevent from burn injury, touching the heat pipes in the glass tubes is strictly
prohibited. The evacuated tubes should not be exposed to direct sunlight before
installation.
Care should be taken not to touch the pipe work as it may be HOT! Plastic pipe is NOT
suited to the water temperature and pressure that may occur in the system.
DO NOT store chemicals or flammable materials near the appliance.
NEVER use a flammable spray such as hair spray, lacquer, paint, etc. near this unit, as
this may cause a fire.
This domestic solar water heating system will reduce your energy bill and protect our
Earth by cutting carbon footprints. The SRCC has published system performance at
different locations within the United States. You can refer to the report or certificate for
details on energy savings.

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SOLAR WATER HEATER PACKAGING & TRANSPORT
All ThermoPower-VTS15-HP and ThermoPower-VTS30-GP appliances (storage
tank, evacuated tubes, support base and connection accessories), are delivered well
packed to the customer.
The storage tank is placed between two round Styrofoam covers of 7 cm each, which
are tightened on the storage tank with stretch film. Then it is placed in a hard carton
pack, on which the indications of each model are displayed on the outside. The frame
and reflector are fixed beside the tank in the same box.
The evacuated tube with heat pipe and aluminum fin is packed with 4 plastic protective
elbows, attached on 4 different positions oon the tube. One box can store 10 or 15 tubes,
and are then packed in a wooden box.

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1. Features of pressurized solar water heater
• High food-grade stainless steel 304 2B. State-of-the-art welding and potable water
status.
• Through the 365° inner tube absorber and reflectors behind the tubes, the heat up
time is very fast from the time the sun rises on the east side of the tube until it sets on
the west side – unlike a flat plate collector, which has a high output during the sun’s
highest radiation level (around midday).
• Year-round utilization, even in cold, windy climates where freezing does not occur
below -2 degrees Celsius for short periods of time.
• Can operate with incoming water pressures of 0.4 MPa – no circulating pump or
controller necessary.
• The system will still function even if some vacuum tubes lose their vacuum or are
accidentally damaged.
• All-day tracking capabilities due to 360° absorber on inner tube.
• The diffuser reflector plate behind the glass tubes adds to the heat gain during blue
sunlight days.
• When installing more than one unit, system can be installed using parallel and/or
series connections, increasing the hot water capacity/supply.

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2. Structure of solar water heater
Component description:
HEAT PIPES: An evacuated-tube collector contains several individual glass tubes,
each containing an aluminum fin and a heat pipe. The heat pipe transfers heat efficiently
to the water in the tank.
WATER TANK: The storage tank is made of three layers: inner shell, intermediate
foam insulation and outer cladding. The shell is built to hold maximum water pressure
of 150 psi. Shell material is corrosion-proof, food-grade stainless steel. Foam insulation
thickness is designed to self-sustainingly maintain the tank water temperature during
continuous overcast days in the coldest wintertime. Outer cladding is normally
galvanized sheet metal, providing a fine surface finish and a long-lasting life.
EVACUATED TUBES: Top-quality double-walled tubes are used. There is an
aluminum or copper-coated mirror on the inside surface of the inner glass wall. The
mirror well traps thermal energy inside the tube. On the metal mirror layer, there is
selective absorption coating, which converts over 99% of the energy from visible and
invisible lights.

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The outer glass wall acts as glazing, creating a vacuum and protecting the coating
against the elements. On the inner surface of tube ends, a silver-colored getter material
is applied, which absorbs the remaining gases inside the tube’s hollow space. Deducting
the absorption and surface reflection of the outer wall of the tube, the overall efficiency
of the tube is over 92%.
REFLECTOR: Reflector is silver-coated reflecting panel. The reflectors can improve
solar system thermal efficiency and reinforce the frame structure.
FRAMES: Frame is made of rustproof material. A frame may have full-length rear legs,
suitable for flat surface installation, or shortened rear legs, suitable for sloped surface
installation. Length of rear legs could be cut to fit at site.
3. Working principle
3.1. Principle of vacuum tube
The vacuum tube is composed of inner tube, outer tube, selective absorption layer,
vacuum space, inspiratory layer. The outer wall of the inner tube is the selective
absorption layer. The space between outer tube and inner tube is the vacuum space. At
the bottom of the outer tube, there is an inspiratory layer which can be used to absorb
the remnant air.
3.2. Working principle of solar water heater
The vacuum tubes absorb solar energy, and the aluminum fin passes the heat energy
to the heat pipe. The liquid medium in the heat pipe is heated by the heat energy, then

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turns into a gas medium. The gas medium flows up to the top of the heat pipe and
transfers the energy to the cold water in the tank, subsequently reverting back to a liquid
medium and flowing down. As the process continues, the water in the tank will become
the hot water.
Fig 3.1 Solar water heater working sketch map

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4. Technical data and product description
4.1 Technical data
Model
ThermoPower-VTS15-HP
ThermoPower-VTS30-HP
Number of Tubes
15
30
Gross area
24.5 ft2
47.9 ft2
Tank Volumetric
Capacity
40 gallons
79 gallons
Weight Empty
143.3 lbs
198.4 lbs
Fill weight
474.0 lbs
925.9 lbs
Length of Tubes
70.9 in
70.9 in
Outer tube diameter
2.3 in
2.3 in
Tube thickness
.06 in
.06 in
Tube Thermal Expansion
3.3×10-6℃
3.3×10-6℃
Absorptive coating
Graded Al-N/Al
Graded Al-N/Al
Absorbency
>92%(AM1.5)
>92%(AM1.5)
Emittance
7%(100℃)
7%(100℃)
Vacuum
P<0.005Pa
P<0.005Pa
Heat Loss
<0.8W/㎡
<0.8W/㎡
Insulation
Polyurethane,55mm
Polyurethane,55mm
Stagnation Temperature
<220℃
<220℃
Maximum working
temperature
90℃
90℃
Maximum Working
Pressure of all circuits
0.6MPa
0.6MPa
Working pressure
0.4MPa
0.4MPa
Maximum wind and
snow load
0.49kN/m²
0.49kN/m²
Tilt Angle
45°
45°
Inlet and Outlet
½ in
½ in
T&P Valve Port
½ in
½ in
Frame
Aluminum Alloy
Aluminum Alloy
4.2 System Tolerance Information
Freeze tolerance limits are based upon an assumed set of environmental conditions.
Extended periods of cold weather, including ambient air temperatures above the
specified limit, may cause freezing in exposed parts of the system. It is the owner’s
responsibility to protect the system in accordance with the Supplier’s instructions if the
air temperature is anticipated to approach the specified freeze tolerance limit.

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4.3 System start-up procedures
After the system installation, check there is no leakage in the system and follow the
following steps to start up the system.
Step 1: Connect Garden Pipe to Drain Valve V4, and keep V4 Open.
Step 2: Open the following valves: V0, V2, V4 and shut off the following valves: V1,
V3, V5
Step 3: Keep the water running for 5 minutes to flush out the solder or stains after the
water from V4 is observed.
Step 4: Shut off V4 and Open V3, and the system is in normal operating status.
4.4 System pipe anti-freezing protections
This is a direct DHW system. The plumbing copper pipe needs anti-freezing protection
when the lowest temperature is below 23 Fahrenheit or -5 Celsius in the coldest climate.
The anti-freezing protection detail is described below.
The tables SRCC uses to evaluate the freeze protection provided by pipe insulation
indicate that 1.5 inches of insulation on a 0.75 inch type L copper pipe will protect the
pipe down to ~14°F. It would be okay for the whole system if all the pipe was insulated
well under this temperature condition.
It would be better to drain down the whole system if the temperature is lower than 14oF
to avoid freezing in the connecting pipe.
In case of black out or power loss during cold weather when the temperature is lower
than 14°F or -10° Celsius, a system drain out procedure must be followed as follows,
and the existing auxiliary water heater must have adequate capacity, listed and labeled
by an accredited listing organization to continue providing adequate hot water.
Step 1: Shut off V2 and V3 Solar Isolation valves to isolate solar system.
Step 2: Open V1 to using auxiliary hot water heater system, and bypass the solar water
system. Ensure the V0 is open.
Step 3: Connect Garden Pipe to both Drain Valve V4 and V5.
Step 4: Put both Garden Pipes in the house drain dock or sinks.
Step 5: Open both V4 and V5 drain valves until no more water comes out of either pipes.
Step 6: Shut off both V4 and V5 drain valves.
When the electricity is back to normal, follow the system start-up procedures to set up
the system to normal operation.
4.5 Specific notices
4.5.1 Auxiliary Hot Water Heater
The system is not a replacement of the existing auxiliary hot water heater. It is installed
upstream of the existing conventional hot water heater. The auxiliary hot water heater
must be maintained as usual. The auxiliary hot water heater must have adequate
capacity, listed and labeled by an accredited listing organization. It should have built-

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in insulation per the accredited organization. If the auxiliary hot water heater doesn’t
come with insulation, it should be covered with minimum R2.2 insulation with
thickness of 1/4”. (GUIDE: 6.1.1.4)
4.5.1 Different metallic materials
To prevent galvanic corrosion, a dielectric union or coupling should be installed in
between the copper pipe and steel tank.( GUIDE: 6.1.1.10)
4.5.2 System Tank (GUIDE: 6.1.3.2)
The direct system comes with a 63-gallon tank, no heat exchanger, hence no extra tank
is needed.
4.5.3 Heat Transfer Fluid (HTF) inside the heat pipe (GUIDE: 6.1.3.6 and 6.3.7)
The HTF inside the heat pipe is a small amount of pure water at a very low pressure.
The heat pipe and HTF are built as one unit, no refill is needed, and the water inside
will not be reduced.
No other fluid shall be used that would change the original classification of this system.
Unauthorized alterations to this system could result in hazardous health conditions.
4.5.4 Temperature Sensor Wiring and System Monitoring (GUIDE: 6.1.5.5 and 6.4.1)
Connect either temperature sensor to the cold water pipe and hot water pipe,
respectively. Put one-foot R4.4 insulation on both sensors. The sensor and pipe
intersection point should be in the middle of the one foot insulation.
To determine whether the solar system is working, observe the thermometer when hot
water is being used in the house. The water returning from the collector on a sunny day
should be at least 10°F warmer than the water going up to the collector. The temperature
of the cold water and hot water is displayed on the monitor.
4.5.5 The insulation of the final 5 feet to the auxiliary water heater (GUIDE: 6.1.6.3)
The insulation of the final 5 feet to the auxiliary water heater shall be insulated with R-
0.46 K m2/W or greater insulation.
4.5.6 Public Traffic Statement (GUIDE: 6.3.17)
Components exposed to public traffic should be maintained below 140°F or
insulated/isolated to prevent any hazards to public traffic.
4.5.7 Components accessibility (GUIDE: 6.4.6)
All components should be accessible for maintenance and servicing.
4.5.8 Installation and Maintenance Practices (GUIDE: 6.5.5 and 6.5.10)
Do not impair enclosure function. Do not allow vermin intrusion. Ensure applicable
codes and National Roofing Contractors Association practices are followed. The entire
system should be checked by the installer once every two years.
Follow applicable codes and practices when penetrating the structure to install solar
system.
4.5.9 Safe practices (GUIDE: 6.5.11)
Building materials adjacent to solar components shall not be exposed to elevated
temperatures.
4.5.10 System mounting (GUIDE: 6.5.12, 6.5.13, 6.5.14 and 6.5.19)
Allocate a place that is not shaded between 10:00AM and 3:00PM, and keep the solar
panel facing south with 45° of adjustment tolerance. The pitched degree of the panel

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should be close to the latitude of the location.
All the piping should be properly supported according to plumbing code. These
supports must not compress the insulation.
Any structural element or fire rated assembly should not be reduced after penetration
during the installation. It will be up to local code to dictate exactly how this is done.
The outdoor pipes should be insulated with R6.6 insulation with thickness at or greater
than 1 inch. The indoor pipes should be insulated with R2.6 with thickness at least 1/4”.
4.5.11 Projected components need to be replaced
The glass vacuum tubes might need to be replaced if broken by unexpected hazards,
such as collision with a hard material. Please contact the installer to order replacement
parts. The battery of the temperature monitor needs to be replaced when the battery is
out. The battery can be purchased at store.
5. Installation of solar water heater
5.1. Frame installation drawing
（Solar Water Heater for Flat Roof ）
1.rear pole 2.triangle plate 3.tank bracket 4.level bar 5.rear support bar
6.front support bar 7.front pole 8.tail stock 9.back box 10.feet
（Solar Water Heater for Sloping Roof ）

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1.back box 2.adjusted end cap 3.front pole 4.front support 5.tank bracket 6.horizontal support
5.2 Installation of frame:
1.front pole and rear pole installation
2. rear level bar and rear support bar installation

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3.front level bar、front support bar and back box installation
5.3 Installation of the tank
Fig 1
Fig 2
Fig 3
Step 1. Screw off the nuts
from the connection bolts
of the water tank. Take the
water tank out. Put it on the
installed frames slowly and
lightly.
Take care to insert the
bolts of the water tank
into the corresponding
connecting holes of the
tank brackets.
Step 2. Install the
accessories and turn the
small red cap of the air
vent on the top to
ventilate.
Step 3. Install the T.P
valve.
5.4 Installation of the heat pipe and vacuum tubes
Open the pack of vacuum tubes and take out one vacuum tube at a time.
a. Install the anti-dust seal on top of vacuum tube.

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b. Insert the vacuum tubes into the water tank slowly, while turning the tube.
5.5 Solar water heater installation and attention
Thisstep requires you to locate your hot water heater. The collector should face
approximately south (plus or minus 20°). Use a declination value from a map or
declination table to determine the direction of true South from the compass reading.
The collector should be tilted at the latitude angle plus 15° for best winter operation and
latitude minus 15o for best summer performance. Tilt at latitude for best year-round
performance.
A good GPS will also provide accurate compass headings and your exact latitude. If
you do not have a compass or GPS, wait until solar noon and the shadow of a vertical
stick or surface will point due North. True South is 180° from true North. HINT: MANY
SOLAR SYSTEMS ARE PLACED AT THE ROOF SLOPE WHICH IS LESS THAN
LATITUDE MINUS 15o, BUT IS MORE AESTHETICALLY PLEASING, WITH
ONLY A SMALL 10% PENALTY IN ANNUAL PERFORMANCE.
The latitude of your location can be found on the Internet or in your local paper. The
latitudes of some selected U.S. cities are presented in Table 5-1 for reference. (HINT:
Look at other solar collectors in your area, see how they are oriented to South and
elevated for latitude). The report includes a solar sitting template to show the effects of
shadowing from trees or nearby buildings, declination map and other useful information
about system sitting.
Table 5-1 Approximate Latitudes of Selected U.S. Cities
City (arranged by increasing latitude)
Latitude (all North)
Anchorage, AK
62°
Juneau, AK
58°

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Seattle, WA
47.5°
Portland, OR; Minneapolis, MN; Bangor
ME
45°
Buffalo, NY
43°
Chicago, IL; Boston, MA; Detroit, MI
42°
Denver, CO; Indianapolis, IN; Philadelphia,
PA
40°
Kansas City, MO; St. Louis, MO;
Washington, DC; Cincinnati, OH
39°
Reno, NV
39.5°
San Francisco, CA; Sacramento, CA
38°
Nashville, TN
36°
Albuquerque, NM; Memphis, TN
35°
Los Angeles, CA
34°
Phoenix, AZ; Charleston, SC
33°
San Diego, CA; Savannah, GA
32°
Houston, TX; New Orleans, LA;
Jacksonville, FL
30°
Tampa, FL
28°
Brownsville, TX; Miami, FL
26°
Honolulu, HI
21°
Hilo, HI
20°
Three reference poses are given below. However, in deciding the specific location and
pose of a unit, the installer should consider:
1) Choose a strong foundation and safe place
2) Location should have optimized sunshine exposure
3) Minimize plumbing length to decrease heat loss
4) Ensure good aesthetic view with the surrounding environment

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5) Perform safe operations to prevent from injury during
.The solar water heater must be installed in locations with wind and snow load lower
than 0.49kN/m². If the wind and snow load in the location is more than this value, please
strengthen the installation of system.
.The best time to install the heat pipes and vacuum tubes is in the morning or in the
evening, or a time when the sunlight is weak. If there is strong sunlight, the heat pipes
will be heated quickly and the temperature will reach above 100°. That will scald the
installation workers easily. Or wrap the vacuum tubes in a piece of cloth so that they
are not exposed to direct sunlight.
.After installing and adjusting solar water heater, connect cousins with building plate
by the inflated bolt. Fix it more than 4 steel ropes to avoid damage from strong wind.
.Be sure there is no leakage in pipeline, joints, valves, etc.
.The pipeline outside must be have heat protection and anti-freezing. In some very cold
areas, an emptier or restrained temperature anti-freezing cable should be added.
.If the solar water heater is not in the protected scope of a lightning conductor fixed on
the building, the user should add the lightning conductor. The local power department
must connect the roof conductive part to the grounding wire with at least 16 mm
grounding cables. For building height (installation height) less than 20 meters, there is
no need to adopt special measures to protect from lightning strikes
. When penetrations are required in structural elements to accompany passage of solar
components, those modified structural elements shall comply with local building codes.
. Building materials adjacent to solar equipment shall not be exposed to elevated
temperatures, which could accelerate their deterioration. Many non-metal roofing
materials will soften in high temperature ranges and begin to degrade.

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. The design and installation of systems shall not impair emergency movement of the
building occupants.
.The installation shall:
. NOT IMPAIR ENCLOSURE FUNCTION
. NOT ALLOW VERMIN INTRUSION
.MEET APPLICABLE CODES AND NATIONAL ROOFING CONTRACTORS ASSOCIATION
PRACTICES
6. Pipeline installation
6.1 Plumbing system schematic map
ThemoPower-VTS15-FP and ThermoPower-VTS30-HP products are solar hot water
heater systems which pre-heat inlet water with solar energy prior to feeding into the
conventional hot water heater. It can be integrated with the existing gas, electric,
propane, or oil hot water heater by installing upstream of the existing hot water heater.
Food grade materials should be used for all water contact areas.
A mixing valve must be installed if the homeowner does not have one currently. Set the
output water temperature at a point of 48.9oC (120oF).
The tank upper temperature limit is 300°F and 130 psig. As the thermosiphon system
has no way to stop the operation of the solar collector, there should always be a T&P
relief valve installed to release some high temperature water out of the tank; then
mains water will charge the tank to keep the tank in normal working condition.
The T&P valve releases some water out of the tank when the temperature is more than
194°F, or the water pressure is above 58 psi to ensure the safety of the system.
The specification of the T&P R is,
Inlet:1/2 in tapered male thread
Outlet:1/2 in parallel female thread
Maximum opening temperature:90℃/99℃
Rated working pressure: 0.4MPa/0.6MPa
Maximum working pressure：1.5MPa
If you are away from your home for a long time and the system will not be used
during that period, we recommend you drain down the system and close the inlet
valve to avoid overheating. In order to prolong the system’s life, cover the collector

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using a canvas cloth or mat.
When the tank gets too hot, please drain down some hot water and then charge the
mains water to cool down the system slowly.
All exposed areas need to be well insulated to resist freezing. The insulated tank keeps
the hot water in the tank from losing too much energy throughout the night. The system
can absorb energy at most weather conditions, even on full cloudy days in winter. The
collector tubes still get energy from infrared heat passing through the clouds on fully
cloudy day.
All labeled valves (V1 to V5) must be installed within an adult’s reach. Draining valves
(V4 & V5) must come with hose bibs that can connect a garden hose for draining
purpose.
Piping should be sloped toward drain ports with a drainage slope of no less than 2 cm
vertical drop for each meter of horizontal length (1/4 inch per foot).
The illustration below is the installation pipe line of pressurized solar water heater.
The directions of each valve and the corresponding positions should match the
illustration. There should be no leakage in the tie-in. The pipe line must have heat
preservation and anti-freezing.
Underground piping subject to vehicular traffic shall be installed to withstand the
additional load applied by this traffic. The trenches and backfill shall be free of sharp
objects in contact with the pipe.
As the system is a solar-only system, there will be some days during which it cannot
meet the user’s heat demand if the solar irradiance is not optimal. It requires auxiliary
hot water heating equipment to ensure that user demand can always be met.
Our system can plumb with electrical, gas, or oil water heater; for connecting detail,
please reference the below diagram. Please note that, when you choose the backup
water heater,
“THE AUXILIARY WATER HEATER MUST HAVE ADEQUATE CAPACITY,
LISTED AND LABELED BY AN ACCREDITED LISTING ORGANIZATION.”
The backup water heater thermostat set point can be 51.7°C (125°F) to meet the final

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delivery water temperature.
Regarding the electrical back up water heater, you can choose to connect both of the
heat elements to speed up heat rate, or you can connect only one on the top of this
water heater. It is best to get advice from the field-wiring installer to ensure all the wire
can meet the heat element’s maximum power.
The above is a reference plumbing connection diagram. The formal plumbing architecture design
and blueprint drawing shall always be done by a licensed architect and signed by licensed
plumbers. Acquire the proper working permits from the local city building department before the
installation. Install the system using a licensed contractor with solar install certificate. Request and
perform the inspection and sign-off after installation.
Important Notice and Warnings
To prevent burn injury, touching the heat pipe in the glass tubes is strictly prohibited. The
evacuated tubes should not be exposed to direct sunlight before installation.
The inlet and outlet port size is ½” tube; you can choose ½” or ¾” pipe size between
the water supply and water tank connections. The safety valve size is also ½”. Make
sure all the safety valves are in normal condition before flushing the system.