Manual 19457 - Solar Pool Heaters by Aquatherm Industries, Inc.
• SAVE INSTALLATION TIME AND AVOID CALL-BACKS •
• READ THIS MANUAL BEFORE MOUNTING COLLECTORS •
SWIMMING POOL
SOLAR HEATING SYSTEMS
INSTALLATION MANUAL
FOR
AQUATHERM INDUSTRIES
SOLAR COLLECTORS
FOR MODEL NUMBERS:
16004-12 16004-10 16004-8
MANUAL CONTENTS
This manual provides a detailed step-by-step procedure for the installation of an Aquatherm
Industries solar pool heating system. If the directions are followed correctly and only recommended
Aquatherm Industries hardware and components
are used, the installed system should provide years
of trouble free service, savings, and enjoyment.
First, you should thoroughly plan the proposed system before installation. Section One of this manual
explains and illustrates the required kits and components. Section Two provides detailed instructions for mounting the collectors and related hardware. Section Three concludes this manual with
instructions for system start-up, check-out and
maintenance.
CAUTION: SOLAR COLLECTORS ARE OFTEN INSTALLED
ON THE ROOFS OF BUILDINGS. UNLESS YOU ARE VERY
FAMILIAR WITH WORKING ON ROOFS AND HAVE THE
PROPER LADDERS AND SAFETY EQUIPMENT FOR
SUCH WORK, YOU SHOULD HIRE SOMEONE WITH THE
NECESSARY EXPERIENCE TO DO THE INSTALLATION.
FAILURE TO OBSERVE SAFE PRACTICES ON A ROOF OR
OTHER ELEVATED STRUCTURE MAY RESULT IN FALLING,
LEADING TO SERIOUS INJURY TO YOU.
1
2
MOUNTING
COMPONENTS
DIAGRAM
2
6
Figure 1
4
4
3
5
SECTION ONE: KITS AND COMPONENTS
REQUIRED TO BUILD A COMPLETE SYSTEM
INSTALLATION KITS AND COMPONENTS
This section provides descriptions and part numbers of the
Aquatherm Industries Installation Kits and components
required for each solar pool heating system. The mounting
location of each kit component is shown by the corresponding circled number in the ‘Mounting Components’ diagram,
shown above.
2 The System Kit (Part #18002-1) Contains additional
hold-down hardware and connecting parts and adapters
needed to complete water connections from the row of collectors to the system feed and return lines. The pipe
adapters that connect the system piping to the collectors
are 1 1/2” high temperature CPVC. The system check valve
is 1 1/2”- 2” PVC. Installation and owner’s manuals are also
included. Use one (1) kit per system.
1 The Collector Installation Kit (Part #18001-1) Contains the
parts needed to fasten a single solar collector to a supporting surface and to make water connections from one collector to another.
Use one (1) kit for each collector.
Qty
Part No.
Description
1
4
2
4
16007-5
30168
60001-1
60546-1
Outlet Header Hold-Down Strap (30”)
Strap Hold-Down Bracket
Collector Connector Hose (3 3/4”)
Hose Clamp
2
Qty
Part No.
Description
1
1
1
2
4
2
4
1
1
1
10003-1
16007-5
30061-1
30089-1
30168
60001-2
60546-1
60019-2
19505
19457
Vacuum Relief Valve
Outlet Header Hold-Down Strap (30”)
End Cap
Pipe Adapter
Strap Hold-Down Bracket
System Connector Hose (7”)
Hose Clamp
Check Valve, 1 1/2” -2”
Owner’s manual (not shown)
Installation Manual (not shown)
3 Optional Supplemental System Isolation Kit (Part
#18003 not shown) Contains additional parts to permit
manual isolation of the solar system from the pool or spa
filtration system. Use one (1) kit per system.
Qty
Part No.
Description
1
1
60019-2
60053-2
Check Valve, PVC 1 1/2” -2”
Ball Valve, PVC 1 1/2” -2”
6 Hold-Down Strap (Part #16007-1, #16007-3)
Polypropylene fabric strap, 5/8” wide, 100 or 300ft. long.
4 Add-A-Row Kit (Part #18005-1) Contains additional
hold-down hardware and connecting parts and adapters
needed to complete water connections of a row of collectors, for systems with more than one row. Used one
(1) for each additional row after the first.
Qty
Part No.
Description
1
1
2
4
2
4
10003-1
30061-1
30089-1
30168
60001-2
60546-1
Vacuum Relief Valve
End Cap
Pipe Adapter
Strap Hold-Down Bracket
System Connector Hose (7”)
Hose Clamp
7 Header Inserts (Part #50055-1) Used in special situations where unusually high stagnation temperatures are
expected, such as in a desert climate, or where abnormally high pressures may occur. Use four (4) inserts per
panel.
5 Row Spacer Kit (Part #18004-1) Contains additional
hold-down hardware and connecting parts and adapters
needed if collectors must be separated by a space due
to roof obstructions, such as a chimney or roof vent. Use
one (1) for each gap between collectors.
Qty
Part No.
Description
4
4
2
4
30089-1
30168
60001-1
60546-1
Pipe Adapter
Strap Hold-Down Bracket
Collector Connector Hose (3 3/4”)
Hose Clamp
Typical High Wind Area Bracket Bolting
3
If the flow rate is below the minimum as shown in the table
above, then the size of the filtration pump or pipe size should
be increased, or a booster pump installed in some cases.
SECTION TWO: INSTALLATION GUIDE
Step 1: Check Water Flow
Select appropriate pipe size for the system supply and
return lines. The headers of the AQUATHERM collectors
are 1 1/2”, and the pipe adapters, included in the kits, connect to 1 1/2” PVC Schedule 40 pipe.
Under normal conditions the existing filtration pump has
adequate flow and head pressure to circulate the pool
water through the AQUATHERM system without significant reduction in flow. However, verifying the flow rates
ensures satisfactory system operation.
To avoid excessive pressure loses, the following minimum
pipe sizes for the supply and return lines are recommended:
In order to receive optimum results, AQUATHERM collectors should operate at or near normal flow rates.
Recommended nominal and maximum number of collectors per row are:
Collector Size, ft.: . . . . . . . . . . . . . . . . . . .4x12 . .4x10 . .4x8
Nominal flow rate per collector, GPM: . . . .5.0 . . .4.0 . .3.25
Minimum flow rate per collector, GPM: . . .3.0 . . .2.5 . . .2.0
Maximum number of collectors in 1 row: . .10 . . . .12 . . .14
Maximum Flow GPM
Pipe Size
40
80
100
120
1 1/2”
2”
2 1/2”
3”
Where the recommended size is not available, or where the
length of the lines exceeds 100 feet, use the next larger size.
For example: nominal flow through a row of 9 collectors,
size 4x10ft. is 9x4 GPM = 36 GPM.
Step 2: Decide on System Layout and Placement of
Collectors
Compare your nominal flow with the flow rate of the pump.
Consult the performance curves from the pump manufacturer if you are not sure. If the flow rate is excessive (more
than 10 GPM per collector), or if the system pressure is
greater than 30 PSI, a bypass line should be installed
between the collector supply and return lines above the
three-way valve.
The basic considerations for the system layout is to
ensure uniform flow across each collector, equal flow
through every collector in the system and that the system
drains automatically when not in operation. This is accomplished with connecting the supply line to the bottom (or
inlet) header, and the return line at the opposite diagonal
flow. The outlet headers must be pitched a vertical distance of at least 8” (20cm) above the inlet headers to
assure proper drainage and performance (40 angle from
horizontal).
If the flow rate is below the minimum as shown in the table
above, then the size of the filtration pump or pipe size should
be increased, or a booster pump installed in some cases.
DIVIDED SYSTEM
ASSEMBLY ON ROOF
Figure 2
4
is non-uniform, the heating capacity of the system will be
reduced.
In systems consisting of more than one row of collectors,
each row must be connected in parallel, and the “reverse
return” outlet (return line) of the lowest row to the outlet of
the top most row, (the highest and/or farthest point of the
system). A divided system requires one Add-A-Row Kit,
Part No 18005-1 for each row of collectors after the first.
Refer to Figure 2.
Figure 3
A more complex divided system is shown in Figure 4. This
also illustrates the application of the Row Spacer Kit to
clear a roof obstruction.
Most small to medium size pools require, and most roof
configurations permit a solar heating system with only one
row of collectors. Refer to Figure 3 for a typical one-row
layout.
Note: To assure equal flow, each row should consist of the
same number of collectors. If particular roof configurations
dictate rows with different numbers of collectors, it may be
necessary to provide balancing and provisions to install a
flow meter or temperature gauges should be made at the
same time. For more complex systems, and/or systems
where supply and/or return lines of each row has several
elbows, it is recommended to install balancing valves and
flow meters or temperature gauges for every row.
Use a divided system when installing more than the recommended maximum number of collectors per row, when
avoiding roof obstructions, or where limited space dictates. This provides uniform distribution of water through
all the collectors. If water distribution through the collectors
Figure 4
5
OUTLET HEADERS
HOLD-DOWN STRAP
3/8” (10mm)
3 3/4” HOSE
VACUUM
RELIEF
VALVE
HEADER
HOSE
LOCATING
SHOULDER
HEADER
SEALING
GROOVE
51”
(130cm)
51”
(130cm)
51”
(130cm)
SHORT
HOSES
SHORT
HOSE
LONG
HOSE
A
PIPE
ADAPTER
OPTIONAL
HEADER
INSERT
B
ABSORBER PLATE
HOSE CLAMP
B
CENTERLINE OF STRAP & HOSE
Figure 5a
PIPE
ADAPTER
C
END
CAP
INLET
VACUUM
RELIEF
VALVE
DISTANCE BETWEEN STRAPS
Collector
Collector
Collector
Collector
Panel Size (A) Distance (B) Distance (C) Distance
in feet
inches
inches
inches
_________
_________
_________
_________
12
40
44
16
10
32
36
16
8
28
26
16
OUTLET
SHORT HOSE
LONG HOSE
HOSE
Figure 5
INLET
FROM
PUMP
ASSEMBLY ON
ROOF DIAGRAM
OUTLET
TO POOL
RETURN
PIPE
ADAPTER
3/4 HEIGHT FROM POOL
TO UPPER HEADER
ALTERNATE VACUUM
RELIEF VALVE LOCATION
(60001-2) can be employed to couple the collectors
together for vent pipes or other obstacles up to 7” in diameter. Mark your 51” centers wherever the outlet header
brackets “fall” on the upper chalk line. With obstructions of
over 7”, such as attic fans and skylights, lay out the panels on either side of the obstruction using a Row Spacer
Kit, Part No 18004-1.
Step 3: Install the Collectors
Refer to Figure 5 throughout this section.
Plan the collector location to allow at least one foot on all
sides of the row(s) of collectors for mounting brackets and
piping.
Roof obstructions, if present, should now be taken into
account to determine the exact collector location.
Collectors can be installed over or around different diameter roof vent pipes or other obstructions. After snapping the
top chalk lines but before marking and pre-drilling for your
outlet header brackets, refer to the following instructions:
For roof vents up to 2” in diameter, the collectors can be
installed directly over these vents. Locate the seam in the
panel nearest to where the vent pipe is to come through.
Separate by pulling up on top plate, and pushing down on
the lower plate. Should a vent pipe protrude near a interlocking seam, it will have to be cut apart. Using a sharp
utility knife, CAREFULLY cut through the seam while
pulling the two plates apart. Lay the collector over the vent
pipe, keeping the vent pipe at least 12 inches away from
a header. It will be easier to complete an installation by
mounting this panel first and then working away from it.
Figure 6
1. Determine the position of the last outlet header holddown bracket for the row of collectors. Mark this point on
the roof. The collector outlet header will be located approximately five (5) inches below this mark. Refer to Figure 6.
With a roof vent pipe of 3” in diameter, the collectors can
be positioned on either side of the vent. Two 7” long hoses
6
2. Using this point, snap a chalkline to the opposite end of
the row. This line should slope down the roof toward the
inlet approximately one (1) inch for each six (6) collectors
in the row.
5. Bring the first collector to the roof and slip the proper
hoses over both ends of the inlet and outlet headers on the
last return collector. The long hoses go on the outlet of the
last collector and the inlet of the first collector. Push UP TO
the hose locating shoulder, but NOT OVER it. Locate a
hose clamp 3/8” (10mm) from the end of the hose in order
to center it on the header groves. This clamp must face up
so as to be accessible for tightening and will not rub
against the mounting surface. Make sure you securely
tighten each clamp with a nutdriver. If a nutdriver is not
available, a “hex” wrench or screwdriver will suffice. THE
HOSE CLAMPS MUST BE LOCATED OVER THE
GROVES IN THE HEADER. Refer also to Figure 5a.
Drill a hole for the first outlet header bracket on the first roof
mark. Use a 1/8” (3mm) drill for 1/4” (6mm) diameter
screws. Measure 51” further along the chalk line, mark and
drill a second hole. Then continue drilling pilot holes all
along the chalkline for the total number of collectors which
you are using for the job.
Figure 7
3. Inject a generous amount of silicone or equivalent high
quality sealer into each hole and onto the surrounding roof
surface. Bolt all the outlet header hold-down brackets to
the roof as shown in Figure 7.
Figure 8
4. Locate the strap hold-down bracket holes using the
information in the table of Figure 5.
6. Position the collectors on the roof so that the center of
the outlet header connection hoses are beneath the
secured outlet header hold-down bracket. Using the 30”
length of strap provided with each kit, loop the strap around
the connection hose, pull both strap ends through the slots
of the bracket and secure the strap in the bracket by tying
the loose ends into a knot as shown in Figure 8.
For example, for 4x10ft. collectors, the top strap is 32 inches below the header, or 32+5=37 inches below the chalkline of the outlet header hold-down bracket. The center
strap is again 36 inches below the center strap, or 16 inches above the inlet header.
Snap chalkline parallel to the outlet header hold-down
bracket line. Do not install the hold-down brackets until the
collectors are in place.
Continue to install all collectors in the row, coupling them
side by side, referring again to Figures 4 and 8.
7
9. Bring the remaining strap end across the panel face
passing through both slots in the bracket located on the
other side of the panels. Pull the straps taut against the
face of the panel. Repeat this procedure for the remaining
hold-down strap. Refer to Figure 11.
10. Secure opposite end of strap as shown in Figure 10.
Repeat this procedure for the other strap.
11. Install the Vacuum Relief Valve in the outlet header of
each row. This will be located at the opposite end of the row
that is connected to the collector outlet pipe. Refer to
Figures 4 and 12.
Figure 9
7. Proceed to the lower chalklines previously snapped on
the roof for the strap hold-down brackets. Mark a hole 2” to
the side of the first panel and continue marking holes on
the chalkline centered exactly between the absorber surfaces until you reach the last collector. Mark the last hole
the same 2” to the side of the last panel. Drill a pilot hole
and apply roof sealant at each of these locations. Bolt the
strap hold-down brackets on the roof. Refer to Figure 9. It
is OK to step on the collectors as long as you stay one foot
away from the top and bottom headers.
12. Install an End cap in the inlet header of each row, opposite the end that is connected to the collector inlet pipe.
Refer to Figures 4 through 12.
13. INSPECT THE INSTALLATION AND CHECK ALL
CLAMPS FOR PROPER POSITION AND TIGHTNESS.
14. FOR HURRICANE OR HIGH WIND AREAS, USE HURRICANE PANEL HOLD-DOWN KIT, Part No 18006. CONTACT FACTORY FOR INSTALLATION INSTRUCTIONS.
Refer to the “System Diagram” Figure 12, throughout this
section. The most common piping configurations use a
pressure filter. The pump draws the water from the skimmer and/or a main drain, forcing it through the filter and
sending it back to the pool through the return lines.
If a fuel-fired heater is installed, it is located between the filter and the return line to the pool. The pipes to and from the
solar collectors are connected to the return line to the pool
before the water enters the fuel-fired heater, if one is used.
Whenever there is more than 40 GPM required flow rate to
the collectors or more than 100 feet of piping used in a system, install 2” piping to and from the panels. Piping to and
from the collectors should be the same type of plastic piping and fittings approved for use with swimming pool filters
and pumps. It is recommended to always use Schedule 40
PVC pipe and fittings.
Figure 10
8. Slip one end of a hold-down strap through the slots in
the strap hold-down bracket at the end of the row. Pull
about 9” of the strap through and slip the loose end of the
strap through the slot closer to the collector and pull it tight
and tie a double knot. Refer to Figure 10.
Although PVC pipe is generally white, black is also available but may be difficult to find locally. If for aesthetics black
pipe is desired, it can always be painted black. Before
painting, the PVC pipe must be wiped with cleaner to
remove the glossy surface coating. This will ensure that the
paint will not flake off prematurely.
Figure 11
8
Figure 12
Use a PVC pipe cutter or a PVC wide-blade saw (not a hacksaw) for cutting pipe. It is important to use both quality cleaner/primer and solvent in gluing a PVC joint. Finally, use a cloth
while either gluing or painting to keep the job a clean one.
sure of the filtration pump may be marginal, the Vacuum
Relief Valve might occasionally allow air to enter the system during operation. To prevent this, it is recommended
to install the Vacuum Relief Valve at the alternate location.
Best suited is the vertical supply line, at a point about 3/4
high from pool to top-most row of collectors. See Figure 5
for location and installation method.
Piping should be supported at intervals of 5’ for horizontal
pipe and 8’ for vertical pipe. Use either galvanized or plastic
clamps. Aquatherm Industries hold-down brackets, Part No.
30168 with strap Part No. 16007-5 used as shown in Figure
8 (outlet header hold-down configuration) are also excellent
pipe hangers.
Optional Isolation Valves
Isolation valves may be installed in the solar system piping so that the pool may be operated while the collectors
are being serviced or during freezing weather. Install a
manually operated ball valve in the solar system inlet line
and a check valve on the solar system return line. Both
valves, available in the Optional Supplemental System
Isolation Kit, Part No. 18003, are made to accept either 1
1/2” pipe or 2” PVC fittings. Make sure that the arrow on
the check valve is pointing away from the collectors, and
that the ball valve and check valve are located as close to
the control valve and outlet “T”, respectively. To make sure
no water is left in the collectors for servicing or during
freezes, remember that the pool pump should be shut off
allowing the collectors to drain naturally before the optional isolation valves are closed.
The above diagram shows an automatic electronic temperature control system with a motorized three-way valve
Piping a manually controlled system is identical, except a
manual three-way valve is in place of the motorized valve.
Observations to some individual components:
Vacuum Relief Valve, Part No. 10003-1
One per row of collectors. It is usually installed at the top
end of the header opposite the header connected to the
return line. However, in installations where the head pres9
MANUAL SYSTEMS
The manual control is with a non-positively sealed threeway valve. Water flows continuously through the solar
collectors when the filter pump is on, but can be diverted
manually by the homeowner if the pool becomes too
warm or during extended cloudy weather. During a threat
of freezing conditions it can also be diverted, by first shutting off the pool pump, allowing the collectors to drain,
diverting the three-way manual valve to the "bypass collector" position and shutting the isolation valves on the
collector feed and return lines. A lower end cap on the
collectors or any of the connecting hoses can be
removed to make sure there is no standing water in the
panels. The filter pump can then be re-started to allow for
normal pool filtration. SECTION 3: SYSTEM START-UP, CHECK-OUT, AND
MAINTENANCE
System Start-up and Check-out for Automatic Systems
To check out the system for proper operation turn on the filter system. Set he temperature control to its highest level.
Switch the control to the "flow through collector" mode. The
"flow through collector" light should come on. The threeway valve will then be sending water thru the collectors, and
air will be purged out of the collectors into the pool return
line for several minutes, and should then clear. The panels
should feel uniformly cool to the touch. Switch the control
to the "bypass collector" mode. The corresponding light will
go on and the three-way valve will be sending water directly back to the pool, bypassing the solar panels. After about
5-10, minutes, feel the solar panels again. They should
have begun to warm up. Now switch back to the automatic
mode. If the sun is still shining on the solar collectors, the
"flow through collector" -light should come on again. Slide
the temperature control downwards, and when you reach
the actual temperature of the pool water, the light will turn
off. The flow bypass collector light will go on again. Slide the
temperature control to maximum. The flow through collector light will go back on. For more detailed information on
the system startup, trouble shooting and valve/control
installation, follow the manufacturers' instructions included
with the automatic control system.
During normal operation of the system when the threeway valve is in the "bypass collector" position all the
water in the panels would drain back through the threeway valve (non-positively sealed) when the filter pump
shuts off. An alternate way to protect against sudden
freezes can be accomplished by running a bypass line
(1/8"-1/4") between the collector feed and return line
above the isolation valves. It is possible that a small
amount of water may be present in the collectors when a
non-positively sealed three-way valve is used and the filter pump is on. If a positively sealed three-way valve is
used, a bypass line as mentioned above is mandatory to
allow for panel drainage.
Manually Controlled Systems
Test system operation with setting the manual three-way
valve for water flow through the collectors. Turn on the
pump and observe air from the collectors and piping being
purged into the pool for the first few minutes of operation.
The collectors should now be cool to the touch.
Automatic Control Systems
The performance of a solar pool heating system can be
improved with the use of an electronic control and motorized three-way valve. The control activates the motorized
valve and either sends water through collectors for heating
(or nocturnal cooling) or automatically bypasses the collectors when the pool is warm enough or insufficient sunlight is available. Refer to the manufacturer's instructions
included with the automatic equipment you use.
Flow Rate Test and Adjustment
With the system running and the sun shining, all collectors of the system should be uniformly cool to the touch,
and the system will be operating at optimum performance. If the system has been installed according to
these instructions, and the collectors connected for diagonal flow with the reverse return principle, this optimum
performance condition will now exist.
Other Equipment
Some pools employ an automatic pool cleaner. This
should be plumbed before the control valve to assure
positive flow to the cleaner at all times. If the pool uses
an automatic chlorinator, this should be plumbed after
the outlet tee on the return to the pool. Systems with rows of collectors of unequal size, but fitted
with balancing valves, may now be adjusted. Open all
balancing valves completely and let the system run for
several minutes. The row(s) which feel(s) warmer to the
touch than the other(s), is currently receiving less flow
then it should for optimum performance. Throttle the
valve(s) of the other (cooler) row(s) step-by-step, each
time waiting for a few minutes, and check the temperature. Once all rows feel uniformly cool, the system is balanced and operates at optimum performance. Should
unexpected problems be encountered, the flow rate must
be checked out more thoroughly. There are two methods:
Supplemental Gas, Oil-Fired, or Electric Heaters
It is desirable to pipe the stand-by heater in a bypass
loop. Refer to the System Diagram Figure 12. Fuel-fired
heaters often create a large pressure drop. By placing
the heater in a by-pass loop, pump size, and electrical
energy requirements may be reduced.
10
Temperature Rise Test Methods
An alternate test method is temperature rise. To prepare
the system for testing, obtain two accurate thermometers. Aquatherm Industries dial thermometers Part No.
60054-1, are excellent for this application. One of these
thermometers is installed in the outlet line from the collectors as shown in the System Diagram Figure 12. The
other is used to check the temperature of the pool water,
to compare it with that of the water leaving the solar collectors. Before installing the thermometer in the outlet
line, immerse both thermometer probes in the pool water
for several minutes to compare the temperature readings. If they are not identical, make a notation of the difference and add or subtract (as appropriate) this difference to or from the reading taken while your are testing.
This is necessary in order to provide an accurate indication of the temperature rise of the water passing through
the solar panels.
BOOSTER PUMP SYSTEMS
In some cases, the pool filter pump may not be able to circulate water at a high enough flow rate to allow for proper panel operation. If so, it may be necessary to replace
the filter pump with a larger one or add a booster pump. If
the pump size is increased, it may also be necessary to
upgrade the filter with one with greater flow ratings.
MAINTENANCE
Winterizing Procedures
The solar collectors should drain automatically each time
the pump cycles off. There are no special requirements
for winterizing the solar collectors. The pool piping should
be winterized as per your normal practice.
In southern parts of the country, pool owners operate
their pools throughout the winter, although light freezing
conditions may occur. The accepted procedure to avoid
freezing of the pool piping and filtration system is to continuously circulate the water.
Turn the pump on and move the flow switch to the
"COLL" position. Observe valve action... it should divert
water through the collectors. After flow through the collectors has continued for at least fifteen minutes, compare the pool water temperature with the temperature of
the water flowing through the outlet line. On an average
sunny day, with the air temperature approximately 700 F
(210 C) the water leaving the panels should be 1 to 70 F
(1 to 40 C) higher than that in the pool. If the water rise is
greater than this, insufficient water is flowing through the
panels. This may be caused by a clogged filter, undersized piping, too many elbows in the piping or an inadequate pump. It is important that the temperature rise
through the collectors be kept as low as possible in order
to deliver the maximum amount of heat to the pool.
When solar heaters are used on a pool under these conditions, anti-freeze precautions should be taken.
AQUATHERM solar collectors are not normally affected
by light freezing. However, in oder to protect appurtenant
components such as end caps and pipe fittings and the
collectors against unusual or severe freezing condition,
one of the following two procedures should be followed.
When freezing weather is imminent:
1. Turn circulating system off and allow solar panels and
piping to drain. Isolate collectors with gate or ball valve in
panel feed line and a check valve in the panel return line.
Switch the solar control panel to the bypass position. The
pool filtering system may then be turned back on. When
freezing conditions have passed, open isolation valves
and switch the solar control panel to "AUTO". Vacuum Relief Valve Test
When the solar system is first turned on, air in the panels
will be expelled into the pool and bubbles will appear.
The appearance of bubbles in the pool should stop after
a few minutes.
2. If isolation valves are not installed in the system,
switch the solar control panel to the "COLL" position so
that water circulates through the collectors. When freezing conditions have passed, switch the solar control
panel to "AUTO". THIS METHOD IS NOT RECOMMENDED WHERE TEMPERATURE LEVELS MAY
DROP SEVERELY.
If, after a few minutes, bubbles continue to be discharged
at the return to the pool, remove the vacuum relief
valve(s) and replace it with an end cap. Relocate the
vacuum relief valve to a position in the inlet piping which
is at a height approximately three-fourths of the elevation
of the collectors, above the pool. Refer to Figure 5.
Annual Service
A quicker alternate method is to first try to reverse the
end cap and the vacuum relief valve on the collector
array to see if this stops the bubbles in the return lines.
If the flow or pump pressure are marginal, the long hoses
on the inlet and outlet piping may collapse. If this condition exists, slip a 2" long piece of 1 1/2" pipe into the center of the hose to prevent this.
Hose Clamps:
In particularly hot climates, such as Arizona and
Southern Florida, the clamps which are used to connect
the solar collectors may become loose. If you notice
leaks around the hose couplings, use a nutdriver to tighten clamps. Do not tighten to the extent that the pipe collapses or the clamp gears strip.
11
COLLECTOR REPAIR
In case of a leak in the collector, one of two easy and permanent on-site repair methods is recommended and will
not void the warranty:
If the leak is at the header where the riser tube is welded to the header, or a leak is anywhere in the riser tube
if the system is located in areas experiencing frost, use
method one.
1) Referring to the figure at the right, locate the tube to
be isolated. (End tube has been shown for clarity.)
Using a sharp utility knife, very carefully cut away
approximately 1" of the tube at both headers. Drive a #10
- #12 sheet metal screw, preferably stainless, into the
hole in the header. The screw must be between 1/2" and
3/4" long. DO NOT OVERTIGHTEN! If the screw strips
out, or if the repair leaks, use a larger screw. If the leak is located in a riser tube in non-freezing climates only, use method two. 2) Locate the leak and with a sharp utility knife cut
through the tube at the leak. Cut the web lengthwise on
each side of the tube about an inch above and below the
leak area, enough so that either section of the tube may
be pushed downward. Insert repair plugs, Part No. 30143 in the tube openings,
one above and one below the leak area. Use a #0 Phillips
head screwdriver inserted into the hollow conical shaped
end of the plug to push the plug into place. Bring the damaged section of the tube back to its former position,
restoring the original appearance of the collector.
1940 Rutgers University Blvd.
Lakewood, New Jersey 08701
1-732-905-9002
Part No. 19457 Rev. 10/04
12
©2004 Aquatherm Industries Solar Pool Heating Systems
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