PoolMasterpro PVC Strip Solar Pool Heating Installation

PoolMasterpro PVC Strip Solar Pool Heating Installation
EcoOnline PoolMasterpro™
PVCn Strip Collector
Solar Pool Heating System
Installation and User Manual - Revised 23/05/2017
Optex Solar Pty. Ltd.
ABN: 88 128 228 884
www.EcoOnline.com.au
email: [email protected]
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved. This publication is protected by copyright law
and unless otherwise specified is for your personal and non-commercial use only. No part of this publication
may be reproduced or distributed by any process, electronic or otherwise, without the specific written
permission of Optex Solar Pty Ltd. Trademarks appearing in this manual are the sole property of Optex Solar
Pty Ltd or their respective owners. Nothing in this publication shall be construed as granting any express or
implied license to use any intellectual property of Optex Solar Pty Ltd otherwise than for personal and
non-commercial use only. Optex Solar Pty Ltd must not, to the full extent permitted by law, be held liable
for any claim, cost (including legal costs), damage, expense, loss (including fines, penalties, set-offs and
consequential loss) or liability arising from the use (or misuse) of any product described in this
publication, unless expressly provided otherwise in this publication. Information as well as any
products described in this publication are subject to change without notice.
PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
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Page 1
Contents
1
Key Terms .................................................................................................................................................................. 3
2
Pre-Installation Suitability & Safety Checklist ........................................................................................................... 4
3
Warranties ................................................................................................................................................................ 5
4
Collector Sizing Guide ............................................................................................................................................... 5
5
Pool Chemistry Compatibility Guide ......................................................................................................................... 5
6
Pump Sizing Guide .................................................................................................................................................... 6
7
Solar Line PVC Pipe Sizing Guide ............................................................................................................................... 8
8
Collector Array Components ..................................................................................................................................... 9
9
Required Components (Not Supplied) .................................................................................................................... 10
10 Required Tools ........................................................................................................................................................ 10
11 Safety When Working at Heights ............................................................................................................................ 11
12 Ladder Safety .......................................................................................................................................................... 11
13 Choosing a Place to Install the Collector Array ....................................................................................................... 11
14 Collector Water Flow Configurations ...................................................................................................................... 12
15 Manifold Length vs Strip Spacing - for Manifold Assemblies Parallel to Roof Slope .............................................. 21
16 Manifold Length vs Angle - for Manifold Assemblies Angled to Roof Slope........................................................... 21
17 Roof Assembly and Attachment ............................................................................................................................. 23
18 Extra Wind Proofing ................................................................................................................................................ 27
19 Collector Installation Order/Procedure .................................................................................................................. 29
20 Painting the PVC Piping ........................................................................................................................................... 29
21 Plumbing Diagrams ................................................................................................................................................. 30
22 Installing the Controller for Independent Systems ................................................................................................. 33
23 Drain-Down, Frost Proofing and Winterization ...................................................................................................... 34
24 Optimizing Collector Pressure................................................................................................................................. 35
25 Checking for Balanced Water Flow through All Collectors ..................................................................................... 37
26 Service and Maintenance Schedule ........................................................................................................................ 37
27 Important Installation Check List ............................................................................................................................ 38
PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
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1
Key Terms
This manual was written to follow guidelines and recommendations given in:


AS 3634 - 1989 Solar heating systems for swimming pools
‘HAZPAK’ produced by the work-cover authority
Please take the time to read this manual before starting any work. Particular attention should be given to text
contained in the following key terms.
Please note EcoOnline has a strong product safety policy; do not install products without reading safety guidelines in
the manual. Please report any product safety issues or near misses to [email protected] no matter how trivial.
Indicates a SAFETY issue that is likely to cause injury or death if the user does not
follow the instructions.
Indicates a SAFETY issue that may cause injury or death if the user does not follow the
instructions.
Indicates a SAFETY issue that may cause injury or property damage if the user does
not follow the instructions
Refers to critically important information related to the correct functioning of the
system.
Refers to useful information for the optimal operation of the system
Why? Italic text is optional reading. Gives extra information and reasoning for recommendations that are
non-obvious and/or counter intuitive.
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2
Pre-Installation Suitability & Safety Checklist
The following outlines mandatory suitability and safety requirements for installing this solar heating system. Please
read carefully, if any of the following requirements cannot be meet the system should NOT be purchased or
installed.
Due to the potential of falling from heights, mounting the solar strip collectors on a roof or
structure at heights should only be undertaken by a professional installer, unless you are
accustomed to and confident of performing the work safely. We strongly recommend the
installer invests in roof safety guard rails and a safety harness system, especially for DIY
applications.
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. Children should be supervised to ensure that they do not play with the appliance.
Collectors are to be used with chlorinated (or otherwise sanitized) pool water ONLY. Do not
use collectors to heat fresh (untreated) water due to the potential for Legionaries bacteria
build up.
Building regulations vary from state to state and MUST override any instructions supplied in
this manual. It is the responsibility of the purchaser/installer to check that installations
comply with any relevant state laws and regulations.
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3
Warranties
EcoOnline™ offers the following Warranties




15 Year pro-rata Warranty on all strip collectors
2 year Warranty on Reltech Pool Pumps
3 year Warranty on Davey Pool Pumps
2 Year Warranty on Dontek Controllers
See EcoOnline.com.au Terms and Conditions page for further details.
Customer please note: WARRANTY IS VOID if collectors are installed:






without a vacuum release valve on the return line,
or a non-return valve on the solar pump outlet (with 6mm drain hole in flap),
or with a grossly oversized pump,
or with water pH less than 7.2,
or without the supplied strainer (for systems independent of the main filter),
or if the collectors are installed below the water level.
Why? Such installations will expose the collectors to debris build up, strong fatiguing
positive/negative pressures and/or chemical attack from hot water. These situations will
have detrimental effects on the collectors which will limit lifetimes.
4
Collector Sizing Guide
An interactive collector sizing calculator can be found on our website at:
http://www.EcoOnline.com.au/product-information/solar-pool-heating/sizing-guide
5
Pool Chemistry Compatibility Guide
This system is not compatible with acidic pool/spa water (pH less than 7.2). Sodium
Carbonate must be added to protect the system from acidic pH (<7). pH should be maintained
between 7.2-7.8 for maximum system longevity.
Why? Acidic water with pH less than 7.0 has excess free H+ ions which like to bond to and
hence break apart polymer carbon and silicon bonds.
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6
Pump Sizing Guide
6.1 A Word on eFLOW-balance™ - Energy Saving Solar Pump Sizing
The quick reference tables below outline conservative Australian Standard pump sizing recommendations.
However, please be aware that substantial energy savings can be realized by choosing a smaller pump. For example
researchers at the University of NSW showed1 that “...electrical energy savings in excess of 80% are achievable for
typical solar collectors operating at flow rates reduced by up to 75%, (from 4.8L/min/m2 to 1.2L/min/m2) while
collector efficiency is only reduced by approximately 10–15%.” A concept we call eFLOW-balance™. To help you
understand the potential savings from this concept we have created an interactive pump sizing simulator which can
be found on our website at:
http://www.EcoOnline.com.au/sizing-calculators/poolmasterpro-strip-pool-heating-pump-sizing
However, if you go with a lower power pump please note:




You will need a slightly larger collector area; the pump sizing calculator will let you know by how much.
You will need to check with the pump manufacture that your chosen pump can still prime reliably at your
pump height.
We highly recommend you use a by-pass line to help your pump to prime reliably, see Installing the
Drain/Equalizer Tube Section 23.3 below.
Lastly you may need to run your main filter pump in the afternoon to help mix the warm water if your pool
volume turnover falls below the 50% - 75% range.
6.2 Quick Reference Solar Pump Sizing for Independent Systems
The two tables below will give you the minimum and maximum Australian Standard pump power recommendations
for independent type systems in input watts (not output watts), these specs should be marked on the pump.
Minimum Recommended Pump Power is Limited by Water Turn-Over Requirements
Pool
Water Volume
20,000 L
25,000 L
30,000 L
35,000 L
40,000 L
45,000 L
50,000 L
55,000 L
60,000 L
65,000 L
70,000 L
75,000 L
80,000 L
1
Minimum
Recommended Flow
50 L/min
63 L/min
75 L/min
88 L/min
100 L/min
113 L/min
125 L/min
138 L/min
150 L/min
163 L/min
175 L/min
188 L/min
200 L/min
For 1st Story Install (3m):
Minimum Input Watts Required
270 Watts (0.36 HP)
290 Watts (0.39 HP)
320 Watts (0.42 HP)
340 Watts (0.46 HP)
370 Watts (0.49 HP)
390 Watts (0.52 HP)
420 Watts (0.56 HP)
450 Watts (0.60 HP)
470 Watts (0.64 HP)
500 Watts (0.68 HP)
530 Watts (0.72 HP)
570 Watts (0.76 HP)
600 Watts (0.80 HP)
For 2nd Story Install (6m):
Minimum Input Watts Required
350 Watts (0.47 HP)
370 Watts (0.50 HP)
400 Watts (0.53 HP)
420 Watts (0.56 HP)
450 Watts (0.60 HP)
470 Watts (0.63 HP)
500 Watts (0.67 HP)
530 Watts (0.71 HP)
560 Watts (0.75 HP)
590 Watts (0.79 HP)
620 Watts (0.83 HP)
660 Watts (0.88 HP)
690 Watts (0.93 HP)
L.N. Cunio, A.B. Sproul, Solar Energy, 86, p1511-17 (2012)
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If you don’t know your pools water volume you can look it up from the table supplied below based on the total
water area and average depth:
Pool Water area vs Average Depth Conversion Table
Waters Area
10 m2
15 m2
20 m2
25 m2
30 m2
35 m2
40 m2
45 m2
50 m2
55 m2
1.3 m
13000 L
19500 L
26000 L
32500 L
39000 L
45500 L
52000 L
58500 L
65000 L
71500 L
1.4 m
14000 L
21000 L
28000 L
35000 L
42000 L
49000 L
56000 L
63000 L
70000 L
77000 L
1.45 m
14500 L
21750 L
29000 L
36250 L
43500 L
50750 L
58000 L
65250 L
72500 L
79750 L
Average depth
1.5 m
1.55 m
1.6 m
15000 L 15500 L 16000 L
22500 L 23250 L 24000 L
30000 L 31000 L 32000 L
37500 L 38750 L 40000 L
45000 L 46500 L 48000 L
52500 L 54250 L 56000 L
60000 L 62000 L 64000 L
67500 L 69750 L 72000 L
75000 L 77500 L 80000 L
82500 L 85250 L 88000 L
1.65 m
16500 L
24750 L
33000 L
41250 L
49500 L
57750 L
66000 L
74250 L
82500 L
90750 L
1.7 m
17000 L
25500 L
34000 L
42500 L
51000 L
59500 L
68000 L
76500 L
85000 L
93500 L
1.8 m
18000 L
27000 L
36000 L
45000L
54000 L
63000 L
72000 L
81000 L
90000 L
99000 L
Maximum Recommended Pump Power is Limited by Collector Area
Collectors
Gross Area
13 m2
17 m2
20 m2
23 m2
27 m2
30 m2
33 m2
37 m2
40 m2
43 m2
47 m2
50 m2
53 m2
Maximum
Recommended Flow
67 L/min
83 L/min
100 L/min
117 L/min
133 L/min
150 L/min
167 L/min
183 L/min
200 L/min
217 L/min
233 L/min
250 L/min
267 L/min
For 1st Story Install (3m):
Maximum Input Watts
340 Watts (0.47 HP)
380 Watts (0.51 HP)
410 Watts (0.55 HP)
450 Watts (0.60 HP)
490 Watts (0.65 HP)
530 Watts (0.70 HP)
570 Watts (0.76 HP)
610 Watts (0.82 HP)
660 Watts (0.88 HP)
700 Watts (0.94 HP)
750 Watts (1.00 HP)
800 Watts (1.08 HP)
860 Watts (1.15HP)
For 2nd Story Install (6m):
Maximum Input Watts
450 Watts (0.61 HP)
480 Watts (0.65 HP)
520 Watts (0.69 HP)
550 Watts (0.74 HP)
590 Watts (0.79 HP)
630 Watts (0.85 HP)
670 Watts (0.90 HP)
720 Watts (0.97 HP)
770 Watts (1.03 HP)
820 Watts (1.10 HP)
870 Watts (1.17 HP)
930 Watts (1.24 HP)
980 Watts (1.32 HP)
6.2.1 Example Pump Sizing
For example, for a large 75,000 Litre pool and 1st story roof your minimum Australian Standard pump specs from the
first table above are 566 Input Watts. If you want to install a 40 m2 collector area for this pool for example, your
maximum pump specs, from the second table above are 656 Input Watts. Pumps well below the minimum specs
may not be strong enough to turn over a sufficient volume of water - while oversized pumps are more expensive to
run for little extra heat gain and may need a ball valve constriction installed depending on the collector’s internal
pressure.
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6.3 Solar Pump Sizing for Booster Systems
For booster type systems you should choose a pump at or just below the minimum
specs in the table above as these systems are already pressurized by the filter pump, or
use the above mentioned pump sizing simulator.
6.4 Filter Pump Sizing for Manual Systems
For manual type systems, running off a main pool filter pump, please check that the main
pump is large enough to accommodate the extra load of supplying water to the collectors
at the required pump height. You should add a 3 meter pressure drop across the collector
array to the pump height.
7
Solar Line PVC Pipe Sizing Guide
The table below will help you choose the correct size PVC pipe for the solar lines running to and from your roof. On
the roof we generally recommend 40mm to match the manifolds. Coming down the roof the pipe size can then be
adapted to the pipe size you have for your solar line ground run i.e. 40mm or 50mm.
Recommended PVC Piping Sizing for Solar Pool Heating System Lines
Anticipated Flow Rate
70 Litres/min
120 Litres/min
200 Litres/min
250 Litres/min
400 Litres/min
880 Litres/min
Absolute Minimum
20mm
25mm
32mm
40mm
50mm
80mm
Ideal PVC Pipe Size
25mm
32mm
40mm
50mm
65mm
100mm
Maximum Pipe Size
32mm
40mm
50mm
65mm
80mm
125mm
If the distance from the pool to the roof collector area is more than 10m we recommend
you use the next size up PVC pipe.
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8
Collector Array Components
1 × 4m2 Strip Collector Kit (number of kits depends on system purchased)
1 × 25m 14 tube PVC
nitrile 160mm
strip role
2 × 40mm PVC
Manifold - 500mm x
14 Tube
28 × tube locking
collars
1 × TreMsil 870
silicon tube
per 4m2 kit
1 × Pipe clamp +
0.5m band for
fixing per 4m2 kit
Other Essential System Components (depending on system purchased)
1 × 32mm/40mm
PVC Vacuum
breaker valve
1 × Can of
silicon lubricant
spray
1 × Drain Down
Kit
For Manual Systems (depending on purchase)
1 × 40mm PVC 3-way Ball
valve
1 × 40mm Spring loaded
non-return valve
2 × 28 locking
collar for
repair kit
1 × In-line
pressure gauge
For Independent Systems (depending on purchase)
1 × Dontek Controller
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1 × 14 joining
barb repair
kit
1 × 40mm PVC strainer
Page 9
9
Required Components (Not Supplied)
You also require some of the following extra items depending on your system. These are available in any plumbing or
hardware store.
Appropriate PVC
piping
Various PVC
plumbing bits
N-type PVC
cement & primer
Fixing screws for
pipe saddles
Cable ties for fixing
thermostat wire
We recommend AS 1477 compliant PVC piping with PN9 pressure rating or greater and
matching PVC fittings be used for all collector array plumbing.
10 Required Tools
- Battery powered hand drill
- Corking gun (for Silicon glue)
- Scissors
- Teflon tape (for any threaded fittings)
- Industrial Ladder
- Old cloth for silicon over spray
- Screwdriver
- Hack saw
- Sun/UV protection
-Tape measure
- Hammer
- Power Lead
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- Safety glasses
- Gloves
- Assorted drill bits
- Tin snips
- Needle nose pliers
Page 10
11 Safety When Working at Heights
WHEN WORKING AT HEIGHTS - SAFETY COMES FIRST. A person can easily fall off a ladder
or roof and be seriously injured. For installations on a roof pitch greater than 22° and/or a
double story house we strongly recommend a highly competent professional installer install
your solar collector array. We strongly recommend the installer invests in roof safety guard
rails and a safety harness system, especially for DIY applications.
The installer should always take the necessary safety precautions:








Choose an appropriate day: cool, dry, calm and partly cloudy.
Plan out your install: make sure you have all required components, tools and have plenty of allocated time.
Only work at heights when you are well rested and alert.
Never work alone, always work with at least one other person.
Always use a safety harness or fall arrest system attached to appropriate roof anchor points.
Wear clothes that fit well but that do not restrict movement.
Use proper non-slip shoes.
Use sunscreen.
12 Ladder Safety
The chance of a falling from a ladder should never be
underestimated. Use only solid industrial grade ladders in good repair
that have been checked for faults.
Note: even a small unexpected movement of the ladder, such as a
small slip, can cause loss of balance and result in a fall.
The ladder should be placed on solid ground and should ALWAYS be
securely anchored at the base and secured at the top to prevent
slipping.
13 Choosing a Place to Install the Collector Array
When choosing a location for your collector array you should consider the following in order of importance:



Shading - the collector array should receive no shading between the hours 10am to 4pm.
Direction - collectors should preferably face northwest for maximum heat collection; however the collector
array can also face any angle between Northeast to West.
Wind - the collector array should be mounted in a relatively sheltered location as much as possible.
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The collector array can face anywhere from West to North-east, with an optimal
orientation of North-west for most areas. South facing orientations are not
recommended, unless the roof pitch is quite flat < 10˚.
14 Collector Water Flow Configurations
All collector array configurations must be installed with a vacuum release valve on the
return line and a non-return valve on the pump side.
14.1 Bottom Feed Basic (Square, Parallelogram or Trapezoid Layout)
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As a general principle for all configurations, water flow in the manifold supply and return
pipe MUST always flow in the same direction to achieve balanced water flow in each
strip. Either up the roof for bottom feed system or down the roof for top feed systems.
Why? Without the third balance pipe water always takes the shortest path, reducing
flow in the higher tube strips.
14.2 Top Feed Basic (Square, Parallelogram or Trapezoid Layout)
Top feed configurations should operate at lower pressure of 50 kPa max, and are not
recommended for areas subject to freezing conditions overnight.
Why? It is impossible for the water to drain full from a top feed system. Freezing
conditions with excess water inside piping can lead to PVC pipes cracking.
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14.3 Narrow Roof Space Multi-Loop Configuration
14.4 Bottom Feed Overlap Serpentine (Square, Parallelogram or Trapezoid Layout)
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14.5 Top Feed Overlap Serpentine (Square, Parallelogram or Trapezoid Layout)
Top feed configurations should operate at lower pressure of 50 kPa max, and are not
recommended for areas subject to freezing conditions overnight.
Why? It is impossible for the water to drain full from a top feed system. Freezing
conditions with excess water inside piping can lead to PVC pipes cracking.
14.6 Bottom Feed Butterfly (for long 25m collector arrays)
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14.7 Top Feed Butterfly (for long 25m collector arrays)
14.8 Multi-Directional Directionally Opposing Bottom and Top Feed Arrays
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Collector arrays that face opposing compass directions are not recommended unless
the roof pitch is less than ~15˚. In this case the temperature sensor should be installed
at an angle that is an average of the two collector array directions. Installations with a
purely south facing facet are still not recommended for southern areas of Australia.
Why? Depending on the location of the roof sensor the controller could turn the system
on with one bank of collectors in full shade.
14.9 Multi-Directional Curve Around Arrays
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Collector facets facing different compass directions should only be installed on flat roofs
with pitch no more than 30˚. In this case the temperature sensor should be installed
facing an angle that is an average of the two collector facet compass directions,
preferably weighted toward the compass direction of the larger area facet.
Why? Depending on the location of the roof sensor the controller could turn the system
on with one bank of collectors in full shade.
14.10 Sharply Tapering Trapezoid Arrays
14.11 Bottom Feed “In Parallel” Split Arrays
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An “in parallel” configuration is recommended for installing two different arrays on any
differing or similar levels. However, a ball valve constriction may be required to limit flow
to the collector array installed at the lower level and/or with the lower pressure drop
(shorter strip lengths).
14.12 Bottom Feed “In Series” Split Arrays
An “in series” configuration is recommended for installing two different arrays on two
different levels with the top of the bottom array higher than the bottom of the top array.
Why? An “in series” configuration ensures that the same amount of water will flow in
each square meter of collector area.
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14.13 Plumbing Configurations Not Recommend
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15 Manifold Length vs Strip Spacing - for Manifold Assemblies Parallel to Roof Slope
For installations where the manifold assembly runs square up/down the roof slope, the spacing between collector
strips will need to be adjusted by cutting the manifold length to suit tile spacing, or other spacing requirements.
Manifold Length
500mm (uncut)
480mm (2nd notch)
460mm (4th notch)
440mm (6th notch)
420mm (8th notch)
400mm (10th notch)
380mm (12th notch)
Required Gap Between Strips
60mm
50mm
40mm
30mm
20mm
10mm
no gaps
16 Manifold Length vs Angle - for Manifold Assemblies Angled to Roof Slope
For installations where the manifold assembly needs to run at an angle to the slope of the roof, the spacing
between collector strips will depend on the manifold angle and manifold length. The template on the next page
shows the manifold length required for 10mm strip spacing at a required manifold angle.
Glue a couple of manifolds first and then check the length on the roof. Length may need to
be adjusted for subsequent manifold additions.
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17 Roof Assembly and Attachment
When working with power or hand tools always follow the safety instructions. Wear the
recommended personal protective apparel. Make sure electrical cables are kept away from
any water and from foreign objects which pose a potential cable severing or crushing hazard.
When using glues, solvents or sealing agents make sure you know and seek the proper first
aid in case of an accident.
17.1 Tile Roof Mounting of Manifold Assembly
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17.2 Corrugated Metal Roof Mounting of Manifold Assembly
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17.3 Manifold Gluing Procedure
Use N-type cement only for manifolds and the vacuum release valve. Never apply
primer or cement to any manifold female part. Work quickly, inert male part into female
socket immediately after cement application. Twist one way then the other to spread
any glue, align tool marks and hold in place for a moment. Wipe any excess to prevent
cement induced stress cracking.
17.4 Connecting the Tubes to the Manifold Barbs
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Take care not to overspray silicon on a critical part of the roof as this will create poor silicon
glue adhesion and a dangerous slippery working environment. Spray toward the manifold
assembly piping only - NOT toward the outgoing tubes. We recommend you use a cloth and
clean your hands regularly.
17.5 Strip Collector Assembly & Gluing
Ensure roof is clean and dry. Any moss will need to be removed using a high pressure
stray. Use supplied TREMsil® Silicone adhesive. If you run out, the brand “Parafix”
outdoor silicon can be used as an alternative and is available at most hardware stores.
Consider the passage of water under the collector. Make sure water can still drain and
run under the collector. On very flat tile you will need to lay a vertical strip of spare
collector tube at periodic lengths to allow drainage under the collector strip.
When stripping the return leg, use a blunt flat head screwdriver to press holes through
weak point in one side of the webbing first. Use needle nose pliers to pull out webbing.
When gluing the strip start from the manifold. Glue the first part then place a couple of
heavy objects such as a brick on an unglued part to stop the glued side of the strip from
being disturbed as you lift the next part of the strip to run silicon under. Move the bricks
along as you glue the next part.
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If you make a mistake and you need to remove the locking collar use a hair dryer or heat
gun to warm the tube. For extra grip use a piece of sand paper around the tube to pull off.
18 Extra Wind Proofing
Coastal region boundaries are smooth lines set in from a smoothed coastline by 50km, 100km or 150km lines.
If you are in Wind Regions B, C or D, or situated on a hill or in open terrain, you will need to increase the above
specified frequency of fixings.
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18.1 Roof Edge Exclusions Zones
Note: Strips installed near or within a roof edge exclusion zone require 2 X the fixing strength
in that local area. Strips installations within a roof corner exclusion zone require 3 X the fixing
strength in that local area.
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19 Collector Installation Order/Procedure
Collectors laid on a flat surface can be walked on without damage. Do not step on a hot
collector with a roof fixing screw underneath it. Take extreme care to use non-slip shoes
and never walk on wet collectors, or just glued collectors.
1) Measure roof and plan out your installation using a diagram first.
2) Lay a few manifolds and collector ends out on the ground and measure where you need to cut them so that
they align with the collector strips.
3) If your manifolds run at an angle you’ll need to check the angle on the roof using the supplied template (see
above) to get the correct manifold spacing.
4) Glue manifolds checking spacing as you go.
5) Lay the two completed manifold assemblies on the roof. In the appropriate place create the looped roof
attachment points for tiles, or perforated band diagonal supports for metal roofs.
6) Lay the manifold on the perforated band attachments and fix very loosely at first using hose clamps.
7) Lay the collector strips out.
8) Cut the collector strips near the base of the respective barb manifold and connect the tubes to the barbs.
9) Glue remaining pipe work and vacuum release valve in place.
10) Tighten the hose clamps to secure the manifolds (while still allowing for some thermal expansion).
11) Drill 8.5mm hole and install pressure gauge on supply line using grommet.
12) Allow 24 hours for the glue to set before pressurizing components.
13) Turn the system on for the first time and check for leaks.
14) Check pressure gauge you may need to reduce or increase pressure using PVC ball valves.
15) With the system running glue the collectors down.
16) Install any remaining components.
20 Painting the PVC Piping
The PVC pipe work can be painted black to match the manifold. Use only water based acrylic paints. Note: black
piping gets hotter in stagnant weather and will require more freedom of movement due to extra thermal expansion.
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21 Plumbing Diagrams
When constructing pipe work consider the thermal expansion of long lengths of pipe work
and the stress this produces on joins. Note: the minimum spacing for PVC 40 pipe supports
is 900m, less for smaller pipes. Use the perforated band to create saddles.
21.1 Configuration 1: Manual/Timer/3-Way Motorized Ball Valve System
Configuration 1: Manual or motorized three way valve (9). (Note: automatic controls are omitted for clarity).
Advantages:
* Does not require an extra pump
* Only filtered water runs through collectors
* Can be retrofitted to pools that don’t have separate
inlet/outlet provisions for solar
* Motorized three way valve and controller can be
retrofitted later
Disadvantages:
* Needs to be turned OFF/ON manually or on timer
* Large mains filter pump needs to run all day for solar
* Requires specialized motorized valve and controller to
automate
* Decreases flow rate and increases pressure in the filter
system
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21.2 Configuration 2: Booster/Retrofit System
Configuration 2: Solar booster pump locked to run with filter pump - requires specific controller Dontek V7RTS.
(Note solar pump 13 should of lower flow than filter pump 4).
Advantages:
* Less extra plumbing is required for solar as compared
to an independent system
*Only filtered water runs through collectors
Disadvantages:
* Requires second pump and special controller
* Large main filter pump & solar pump need to run all
day for solar
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21.3 Configuration 3: Independent/Separate System
Configuration 3: Solar pump can run independent of filter pump. Note A and B are the recommended temperature
sensor installation zones for the Dontek controller
Advantages:
* More energy efficient as a small solar pump runs
independent of the large main filter pump
Disadvantages:
* Requires separate solar suction provisions and extra
solar lines to be installed
This system requires separate/independent Australian Standard approved suction and
return lines going into your pool. If you need to retro fit these you must contact a pool
builder.
An inline strainer (14) must be supplied & installed for this configuration. Please note: a
pumps main lint pot is insufficient for this task and will over time result in irreparable
blocking of tubes.
21.3.1 Installing the Strainer for Independent Systems
Install the strainer as shown in the plumbing diagram above with the clear
side down. If the strainer is installed below the waterline you should install a
PVC ball valve to isolate the strainer for cleaning purposes. Depending on the
level of pool use and debris in the pool the strainer may need to be cleaned
regularly. Use a jet of water.
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22 Installing the Controller for Independent Systems
Please refer to the controller manual as different controllers have specific installation instructions. Here we only add
supplemental instructions; they should not override any specific controller instructions. Note: controller manuals are
downloadable from the EcoOnline website.
22.1 Installing the Roof/Hot Sensor
If your controller comes with a long 20m cord hot roof sensor it should be adhered using silicon to a sun exposed
roof tile (or section of corrugated metal for metal roofs) and NOT onto the actual PVC collector strips. Ideal
placement is within arm’s length of the gutter next or under to the collector strips.
If the cord is too short the sensor can also be located on any unshaded “roof proxy”
surface that faces the same part of the sky as the collector strips to approximate the
surface temperature of the roof itself. Alternatively, it can be extended see below.
22.2 Installing the Pool/Cold Sensor
The cold sensor should be fitted inside a section of PVC suction line (before the solar pump) and sealed using the
grommet supplied. For this you will need to drill a hole in the suction line, please check the controller manual for the
recommended size.
PVC plastic should be preheated to 40˚C using a heat gun or it may split when drilling.
You should practice on a pipe off cut as certain drill bit types can “bight” hard into PVC and
the drill can “kick”. We recommend a step drill bit. A cone shaped rolled up piece of
sandpaper can be used to even out or increase the diameter of the hole if you don’t have
the exact size drill bit.
22.3 Extending Sensor Cords
The sensor cords can be extended using similar type cord but in a larger gauge wire. Note, the Dontek cold sensor
uses a shielded type cord; hence you will need the same type (but in a higher gauge) if extending it. Please contact
Dontek or Ascon if unsure.
When extending the cord we recommend a “lap splice” solder join with adhesive heat shrink.
Solder joins should not placed in any conduit section running under ground.
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23 Drain-Down, Frost Proofing and Winterization
23.1 Drain Down
All pool heating systems have a drain down design and MUST drain as fully as possible when the system stops.
The use of a water tight non-return valve on the solar supply will prevent drain down
which could result in water freezing inside PVC piping in frost prone areas and/or hot
water stagnation in summer. Any non-return valves installed on the supply line MUST
have a 6mm drain hole drilled in the flap to allow drain down. Why? The main purpose
of the non-return valve is to prevent a large volume of water from spinning the pumps
rotor backwards when the pump stops. A 6mm hole allows slow drain down while also
preventing hammer action in the flap when the pump stops.
23.2 Winterization
Your collector strips as well as your solar booster pump will require regular winter flushing, you should make sure
the controller you have has a winter mode. If you do not want to run your system over winter you can winterize your
system by draining the solar side of the system, disconnecting the solar booster pump and flushing the pump with
clean water for storage over winter.
PVC piping should be installed with a slope such that all water drains out of the piping to
when the pump stops to ensure a freeze proof system. There should be no U-bend water
traps - these can freeze over and burst plumbing lines in the winter. Note: PE lines are not
affected as these are frost impervious.
23.3 Installing the Drain/Equalizer Tube
A drain tube can be used to drain non-self draining sections of PVC piping in frost prone areas. In some cases where
there are issues with pump priming and a perfectly sealing non-return valve (8) is require; a drain tube can be
installed on the supply and return solar lines leading up to the roof, approximately one metre above pump level to
create an alternative drain down mechanism.
To install, drill into the PVC pipe using an 8.5mm drill. Note: PVC plastic should be
preheated to 40˚C using a heat gun or it may split when drilling. Insert the rubber
grommet into the hole tapered end first.
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24 Optimizing Collector Pressure
24.1 Installing the Pressure Gauge
The pressure gauge must be installed on the roof, on the lowest part of the supply
line. Drill into the PVC pipe using an 8.5mm drill. Insert the rubber grommet into the
hole tapered end first. Use pink Teflon tape on brass tread, lubricate the brass barb
with silicon spray prior to insertion into the grommet. Note: PVC plastic should be
preheated to 40˚C using a heat gun or it may split when drilling.
24.2 Pressure Check Procedure
Stream height
No flow
Collector Pressure
(in return line)
Negative
0.5 Meter
1 Meter
7.5 kPa
15 kPa
1.5 Meter
22.5 kPa
Pressure Adjustment Advice
Install ball valve brake (16) (see plumbing diagrams) to
increase back pressure in return line
Pressure is ideal no action required
Pressure is still okay no action required
Borderline excessive pressure - install extra pool returns
or reduce pump power or install flow limiting ball valve
Collector Type
Bottom Feed System
Top Feed System
Gauge Pressure Range
(in supply line)
10-75kPa max
10-50kPa max
24.3 Negative Pressure & Air Bubble Issues
If the pump height is substantial and you have more than one return outlet to your pool, it may be the case that your
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pump cannot positive pressurize the vacuum release valve. In this case you will get undesirable constant bubbling in
the outlet to the pool as the vacuum release valve is at negative pressure and is drawing in air. If this happens you
will need to install the down draft/brake PVC ball valve (16) on the return line, see plumbing diagrams.
Use the below procedure for solving air bubbling issues, DO NOT remove or drop the
level of the vacuum release valve or increase pump strength. The vacuum release valve
MUST be mounted as specified to ensure collectors are not pressure worked.
The following procedure need be carried out only once during installation. Remove with the vacuum valve’s top and
gasket.
1) Start the system and wait for it to settle.
2) Constrict flow in the return line using the ball valve brake (16, see plumbing diagrams) lever handle by a
small increment.
3) If after some time air bubbling continues, constrict flow by another small increment.
4) If air bubbles stop reliably at this point then the vacuum valve is now at the required positive pressure.
5) Leave the ball valve brake at this setting/constriction permanently (remove handle).
6) If the required constriction is greater than 50% you will need a stronger pump.
24.4 Adjusting the Three Way Valve for Manual Systems
The following procedure for manual system Configuration 1, need be carried out only once during installation. This
procedure can be carried out with the vacuum valve’s top (and gasket removed).
1) Open the three way ball valve (9, see plumbing diagrams) using the lever handle by a small increment.
2) Wait to see if there is sufficient flow and back pressure to create positive pressure at the vacuum valve (7).
3) If after some time air bubbling is still present in the return line, open the three way valve (9 see plumbing
diagrams) by another small increment.
4) If air bubbles stop reliably at this point then the vacuum valve is now at the required positive pressure.
5) Fix in place a back stop on the ball valve lever handle at this travel point, as this will be your maximum
opening point for your three way valve when turning the heating system on again.
24.5 Optimizing Pressure for Oversized Pumps
Over-sized pumps and flow rates could potentially limit the lifetime of your collectors
due to pressure working. Note, the return line to the pool MUST be unconstricted, with
an appropriate number of pool outlets so as not to create significant back pressure.
For an over-sized solar pump (13, see plumbing diagrams) we recommend the following procedure, carried out only
once during installation, to limit pressures inside the panels. This procedure can be carried out with the vacuum
valve’s top (and gasket removed).
1) Removed any potential constrictions in the return line going back into the pool such as eyeballs in the return
outlets.
2) If pressure is still too great (as measured by the above “Pressure Optimization Test”) install a limiting ball
valve just above or below the non-return valve (8, see plumbing diagrams).
3) Turn the solar pump on with the limiting ball valve fully open (if the pump is very strong constricted it to
start with).
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4)
5)
6)
7)
Constrict the ball valve in small increments until stream height is between 0.5m to 1m in height.
Replace vacuum valve’s top part and gasket.
If the required limiting ball valve constriction is too great we recommend a smaller pump.
Permanently fix the PVC ball valve in place by removing the handle.
25 Checking for Balanced Water Flow through All Collectors
At midday with the sun shining on the collectors and the pump operational, run your hand over every part of each
collector in the array. The collector tube near the supply should be cool to the touch while the tubes near the return
should be only slightly warmer to the touch. No part of any collector should be hot to the touch. Hot spots indicate
that there is no or little water flow through this part of the tubes.
During operation the outlet water flow should be strong with a temperature no greater
than about 1-5°C that of the inlet. Faster flows rates will result in a lower temperature
difference across the collector array and hence will maximize collector efficiency; however
this should be balanced against electricity usage. A 2-5L/min/m2 flow is ideal.
26 Service and Maintenance Schedule
Important: before carrying out any system maintenance you MUST check for any manual
and or technical service bulletin updates and download the latest installation manual
from www.EcoOnline.com.au/downloads
Maintenance Issue - Service Procedure
Strainer – Depending on pool usage and level of debris you may
need to clean the strainer regularly.
Leaks – A leak check should be performed as leaks can corrode
metal roofs and gutters. Any leak should be repaired.
Non-Return Valve – The non-return valve (8 see plumbing
diagrams) is a critical system component. It should be checked
that the 6mm hole drilled in the flap has not become blocked
and that the collectors drain fully when the pump stops.
Vacuum Release Valve – The vacuum release valve (7) is a
critical system component. It should be checked that it is not
weeping corrosive water onto the roof.
Plumbing Degradation – Plumbing should be checked for signs
of UV and/or chemical damage. Replace as needed.
Debris Accumulation – Check that there is no build up of debris
around pipe work or collectors, and that water has a clear path
to run down.
Winterizing System – You may need to prepare your system for
winter dormancy each year.
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Monthly
Quarterly
Annually
X
X
X
X
X
X
X
Page 37
26.1 Collector Puncture Repair Procedure
Locate the leak, cut a 3mm cross section of tubing, strip webbing, and thread the
locking sleaves. Lubricate barb joiner using silicon spray. Join tubes using the barb
connector. Lubricate and slide on locking collar, using a blunt object, such as the
back of a kitchen spoon.
27 Important Installation Check List
Your installation should have the following elements:
Correctly sized pump or pressure optimization carried out.
A third balance pipe must be installed for all collector arrays.
For independent systems not going through the filter, the supplied strainer MUST be installed.
The supplied vacuum release valve MUST be installed on the roof on the return line.
Smooth flow is achieved; no air bubbling is present in pool after initial purging.
A hot spot check was performed. All tube lengths are cool during full sun exposure, indicating water flow.
A non-return valve was installed (with a small 6mm hole drilled in the flap).
The drain/equalization tube was installed on the supply and return line.
Collectors should run and be adhered to the top of ridges of any roof structure, not the valleys to allow water
and debris drainage.
Frost proofing was considered. All PVC lines are sloped such that water runs back into the pool at night.
Solar controller roof sensor was mounted on the roof and not on a solar collector.
Extra silicon adhesive was used for collectors near roof exclusion zones (near roof edges).
Pipes and manifold assemblies are mounted above roof valleys to allow clear drainage of water and debris.
The pressure gauge was installed on lowest part of the supply line on the roof, near the first manifold.
User is aware of the maintenance schedule.
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