aquatherm industries solar pool heating installation manual

aquatherm industries solar pool heating installation manual
AQUATHERM INDUSTRIES SOLAR
POOL HEATING INSTALLATION
MANUAL FOR THE EAGLE CLAW
MOUNTING SYSTEM
Part #19001
Rev. 1/2015
SAVE INSTALLATION TIME AND AVOID CALL-BACKS
READ THIS MANUAL BEFORE MOUNTING COLLECTORS
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.
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.
C HAPTER 1
Mounting Components
C HAPTER 1: M OUNTING C OMPONENTS
Contents
*. Overview
1.Collector Installation Kit
2.System Kit
2A.Optional Supplemental System Isolation Kit
3.Hold-Down Strap
4.Add-a-Row Kit
5.Row Spacer Kit
6.Outlet Header Clamp Assembly
7.Aluminum Outlet Header Clamp Assembly
8.Tile Standoff Bracket
9.Outlet Header Bracket
10.Optional Supplemental High Wind Area Collector Hold-Down Kit
11.Header Insert
12.Pipe Brackets
13.Black Hose Clamps
14.Header Spacers
15.Collector Repair Plugs
16.Collector By-Pass Check Valve
17. Flashing, Base and Cover
3
C HAPTER 1: M OUNTING C OMPONENTS
Overview
This section provides descriptions and part numbers of the Aquatherm Industries Installation Kits 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.
I NTERACTIVE 1.1 Mounting Components
1) Collector Installation Kit
2) System Kit
3) Hold-Down Strap
6) Double Hole Outlet Header Bracket
7) Aluminum Header
Clamp Assembly
4) Add-a-Row Kit
5) Row Spacer Kit
2A) Optional Supplemental
System Isolation Kit
1
2
3
4
5
6
7
8
Go to: Chapter 1 Home Page.
4
C HAPTER 1: M OUNTING C OMPONENTS
1) Collector Installation Kit
Part #12034-1 for 1 1/2” kit; #12034-2 for 2” kit
Contains the parts needed to fasten a single solar collector to a supporting surface and to make
water connections from one collector to another. Hold-Down Strap is not included and must be
ordered separately.
Use one (1) kit per collector.
Part No
Qty 1 1/2”
Qty 2” Description
10008-1
1
__
Outlet Header Hold-Down Bracket Assembly
10008-2
__
1
Outlet Header Hold-Down Bracket Assembly
30340-1
1
1
Flashing Base, Outlet Header
30340-2
2
2
Flashing Base, Strap Bracket
50006
2
2
Hold-Down Strap Bracket
60003-1
4
__
Hose Clamp, Stainless Steel
60003-2
__
4
Hose Clamp, Stainless Steel
60690-1
2
__
Collector Connector Hose (3 3/4” long)
60690-2
__
2
Collector Connector Hose (3 3/4” long)
Image 1.1 Collector Installation Kit
Go to: Chapter 1 Home Page.
5
C HAPTER 1: M OUNTING C OMPONENTS
2) System Kit
Part #12135-1 for 1 1/2” kit; #12135-2 for 2” kit
Contains additional hold-down hardware, connection parts and adapters needed to complete
water connections from the collectors to the system feed and return line. The pipe adapters that
connect the system piping to the collectors are high temperature CPVC. The system check valve is
1 1/2” - 2” PVC. Installation and homeowner manuals are also included.
Use one (1) kit per system.
Part No
Qty 1 1/2” Qty 2” Description
10003-1
10003-2
10008-1
10008-2
10011
30061-1
30061-2
30089-1
30089-2
30340-1
50069
60003-1
60003-2
60019-2
60691-1
60691-2
19001
1
__
1
__
4
1
__
2
__
5
4
4
__
1
2
__
1
19697
1
__
1
__
1
4
__
1
__
2
5
4
__
4
1
__
2
1
1
Vacuum Relief Valve
Vacuum Relief Valve
Outlet Header Hold-Down Bracket Assembly
Outlet Header Hold-Down Bracket Assembly
Hold-Down Strap Clamp Assembly
End Cap
End Cap
Pipe Adapter
Pipe Adapter
Flashing Base, Outlet Header
Hold-Down Strap Bracket
Hose Clamp, Stainless Steel
Hose Clamp, Stainless Steel
Check Valve (1 1/2” & 2”)
System Connector Hose (7” long)
System Connector Hose (7” long)
Installation Manual (not shown)
Owner’s Manual (not shown)
Image 1.2 System Kit
Go to: Chapter 1 Home Page.
6
C HAPTER 1: M OUNTING C OMPONENTS
2A) Optional Supplemental System Isolation Kit
Part #12033-5
Includes a 1 1/2” -2” PVC union ball valve and a 1 1/2” -2” PVC check valve to permit manual
isolation of the solar system from the pool or spa filtration system.
Use one (1) kit per system.
Part No
Qty
Description
60019-2
1
Check Valve, PVC 1 1/2” -2”
60053-2
1
Ball Valve, PVC 1 1/2” -2”
Image 2 A Optional Supplemental System Isolation Kit
Go to: Chapter 1 Home Page; Optional Isolation Valves.
7
C HAPTER 1: M OUNTING C OMPONENTS
3) Hold-Down Strap
Part #10035-1 for 54’; #10035-2 for 107’; #10040 for 1400’
Required to secure collectors to the mounting surface. Use strap #10035-1 (54 ft) for rows of up to
6 collectors with two straps or #10035-2 (107 ft) for rows of up to 12 collectors with two straps.
Additional strap is required when using Optional Supplemental High Wind Area Collector HoldDown Kit. Available in bulk, #10040 (1400 ft. roll.)
Image 1.3 Hold-Down Strap
Go to: Chapter 1 Home Page.
8
C HAPTER 1: M OUNTING C OMPONENTS
4) Add-a-Row Kit
Part #12043-1 for 1 1/2” kit; #12043-2 for 2” kit
Used when more than one row of collectors is to be installed. The kit contains additional holddown hardware, connecting parts, and adapters.
Use one (1) kit for each collector row after the first.
Part No
Qty 1 1/2”
Qty 2”
Description
10003-1
1
__
Vacuum Relief Valve
10003-2
__
1
Vacuum Relief Valve
10008-1
1
__
Outlet Header Hold-Down Bracket Assembly
10008-2
__
1
Outlet Header Hold-Down Bracket Assembly
10011
4
4
Hold-Down Strap Clamp Assembly
30061-1
1
__
End Cap
30061-2
__
1
End Cap
30089-1
2
__
Pipe Adapter
30089-2
__
2
Pipe Adapter
30340-1
5
5
Flashing Base, Outlet Header
50069
4
4
Hold-Down Strap Bracket
60003-1
4
__
Hose Clamp, Stainless Steel
60003-2
__
4
Hose Clamp, Stainless Steel
60691-1
2
__
System Connector Hose (7” long)
60691-2
__
2
System Connector Hose (7” long)
Image 1.4 Add-a-Row Kit
Go to: Chapter 1 Home Page; Special Systems Layout.
9
C HAPTER 1: M OUNTING C OMPONENTS
5) Row Spacer Kit
Part #12017-1 for 1 1/2” kit; #12017-2 for 2” kit
Used when a row of collectors must be interrupted by a space to allow for obstructions such as a
chimney or roof vent. It contains the hardware needed to space around any width obstructions by
connecting appropriate lengths of PVC pipe to the pipe adapters at the inlet and outlet headers of
the two collectors on either side of the obstructions.
Use one (1) for each gap between collectors
Use when required.
Part No
Qty 1 1/2”
10008-1
1
10008-2
Qty 2”
Description
__
Outlet Header Hold-Down Bracket Assembly
__
1
Outlet Header Hold-Down Bracket Assembly
10011
4
4
Hold-Down Strap Clamp Assembly
30340-1
5
5
Flashing Base, Outlet Header
30089-1
4
__
Pipe Adapter
30089-2
__
4
Pipe Adapter
50069
4
4
Hold-Down Strap Bracket
60003-1
4
__
Hose Clamp, Stainless Steel
60003-2
__
4
Hose Clamp, Stainless Steel
60690-1
2
__
Collector Connector Hose (3 3/4” long)
60690-2
__
2
Collector Connector Hose (3 3/4” long)
Image 1.5 Row Spacer Kit
Go to: Chapter 1 Home Page; Mounting the Solar Collectors;
Installation Over Roof Vent Pipes; Special Systems Layout.
10
C HAPTER 1: M OUNTING C OMPONENTS
6) Outlet Header Clamp Assembly
Part #10121; #12141 for bulk quantity of 25 including 50 locking screws
Used as supplemental outlet header mounting in conjunction with the Outlet Header Hold-Down
Bracket assembly, Part #10008-1. The bracket is made from high-strength glass-reinforced
polypropylene and is designed for installations that require more flexibility for the outlet header
mounting hardware location, such as barrel tile roofs or installations that require additional
mounting hardware to be anchored into rafters or beams.
Can be used for both 1 1/2” and 2” headers. It is shipped with the insert for 1 1/2” headers
preinstalled. For 2” Headers remove this insert by pulling it apart. See exploded view below.
Image 1.6 Outlet Header Clamp Assembly
Go to: Chapter 1 Home Page; Step Seven.
11
C HAPTER 1: M OUNTING C OMPONENTS
7) Aluminum Outlet Header Clamp Assembly
Part #10117-1 for 1 1/2”; #10117-2 for 2”
Used as supplemental outlet header mounting in conjunction with the Outlet Header Hold-Down
Bracket assembly, Part #10008-1. The bracket is designed for installations that require more
flexibility for the outlet header mounting hardware location, such as barrel tile roofs or
installations that require additional mounting.
Image 1.7 Aluminum Outlet Header Clamp Assembly
Go to: Chapter 1 Home Page; Step Seven.
12
C HAPTER 1: M OUNTING C OMPONENTS
8) Tile Standoff Bracket
Part #50068
For use with barrel tile roofs in place of Hold-Down Strap Bracket,Part # 50006, for strap holddown.
Image 1.8 Tile Standoff Bracket
Go to: Chapter 1 Home Page.
13
C HAPTER 1: M OUNTING C OMPONENTS
9) Outlet Header Bracket Options
Part #50005: Single Hole Outlet Header Bracket
Part #50069: Double Hole Outlet Header Bracket
May also be used to terminate a strap run in high wind areas where extra hold-down strength is
required.
Image 1.9 Single Hole Outlet Header Bracket
Image 1.9 a Double Hole Outlet Header Bracket
Go to: Chapter 1 Home Page.
14
C HAPTER 1: M OUNTING C OMPONENTS
10) Optional Supplemental High Wind Area Collector
Hold-Down Kit
Part #12035-1 for 1 1/2”, #12035-2 for 2”
Used in addition to the basic collector installation kit in regions where high winds are prevalent.
Requires twice the amount of Hold-Down Strap.
Use (1) kit per system.
Part No
Qty 1 1/2”
Qty 2”
Description
10002-1
1
__
High Wind Hold-Down Assembly
10002-2
__
1
High Wind Hold-Down Assembly
30340-1
1
1
Flashing Base, Outlet Header
30340-2
2
2
Flashing Base, Strap Bracket
50006
2
2
Hold-Down Strap Bracket
Image 1.10 Optional Supplement High Wind Area
Collector Hold-Down Kit
Go to: Chapter 1 Home Page; Installation in High Wind Areas.
15
C HAPTER 1: M OUNTING C OMPONENTS
11) Header Insert
Part #50055-1 for 1 1/2”; #50055-2 for 2”
Used in special situations where unusually high stagnation temperatures are expected, such as in
a desert climate or where abnormally high system pressures may occur.
Use four (4) inserts per collector.
Image 1.11 Header Insert
Go to: Chapter 1 Home Page; Annual Inspection.
16
C HAPTER 1: M OUNTING C OMPONENTS
12) Pipe Bracket
Black- Part #30272-1 for 1 1/2”; 30272-2 for 2”
White- Part #30284-1 for 1 1/2”; 30284-2 for 2”
Used for supporting feed and return line piping on the roof or other mounting surface. The Pipe
Brackets are made from a high-strength glass-reinforced polypropylene. Insert the attached
wedge to allow for pipe expansion and contraction.
Image 1.12 Pipe Brackets
Go to: Chapter 1 Home Page; System Piping Overview.
17
C HAPTER 1: M OUNTING C OMPONENTS
13) Black Hose Clamps
Part #60548-1 for 1 1/2”; #60548-2 for 2”
Our standard stainless steel hose clamps with an aesthetic black, durable electrostatically applied
powder-paint coating.
Image 1.13 Black Hose Clamps
Go to: Chapter 1 Home Page.
18
C HAPTER 1: M OUNTING C OMPONENTS
14) Header Spacers
Part # 30017-1, -2, -3, -4 and -5 for 1 1/2”; #30159-1, -2, -3, -4, -5 for 2”
Use instead of the Row Spacer Kit for gaps in between the collectors. Each Header Spacer requires
the use of two additional hose clamps and either two additional Collector Connector Hoses or four
System Connector Hoses depending on the width gap desired.
See Table 1 for Row Spacer Dimensions and Diagram 1 for Row Spacing.
Image 1.14 Header Spacer
Go to: Chapter 1 Home Page; Mounting the Solar Collectors;
Installation Over Roof Vent Pipes; Special System Layouts.
19
C HAPTER 1: M OUNTING C OMPONENTS
9) Header Spacers Cont.
T ABLE 1 Row Spacing Dimensions
Return to : Header Spacers.
20
C HAPTER 1: M OUNTING C OMPONENTS
9) Header Spacers Cont.
D IAGRAM 1 Row Spacing Diagram
Return to : Header Spacers.
21
C HAPTER 1: MOUNTING COMPONENTS
15) Collector Repair Plug
Part # 30143
Used as an easy and permanent on site repair of a collector by isolating the leaking riser tube.
Image 1.15 Collector Repair Plugs
Go to: Chapter 1 Home Page; Repair Plug.
22
C HAPTER 1: MOUNTING COMPONENTS
16) Collector By-Pass Check Valve
Part # 60717
Image 1.16 Collector By-Pass Check Valve
Go to: Chapter 1 Home Page; Collector By-Pass Check Valve.
23
C HAPTER 1: MOUNTING COMPONENTS
16) Flashing Base
Part #30340-1 for Outlet Header Bracket; # 30340-2 for Strap Bracket
Image 1.17 Flashing Base, Outlet Header
Image 17 a Flashing Base, Strap Bracket
Go to: Chapter 1 Home Page.
24
C HAPTER 2
Mounting the Solar Collectors
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Contents
*. Overview
1. Outlet Header Bracket Locations
2. Drill Along Chalkline
3. Outlet Header Bracket Sealant
4. Hold-Down Strap Bracket Locations
5. Install Hose
6. Install Outlet Header Bracket with Hose
7. Header Clamp Assembly
8.Install Hold-Down Strap Bracket
9. Install Strap
10.Install Vacuum Relief Valve
11.Install End Cap
12.Final Inspection
13.Installation in High Wind Areas
14.Installation Over Roof Vent Pipes
26
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Overview
When mounting the collectors, always make provisions for inlet connections at the bottom header and outlet
connections at the top. The outlet headers must be pitched a vertical distance of at least 1/8” per foot
above the inlet headers to assure uniform flow and proper drainage to prevent freezing. 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 consideration 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:
• With roof vents up to 2”(50mm) 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 the vent pipe protrude near a sonic tack weld, it will have to be
cut apart. Using a sharp utility knife, cut through the weld while pulling the two plates apart. Lay the
collector over the vent pipe, keeping the vent pipe at least 12 inches (30cm) away from a header. It will be
easier to complete an installation by mounting this panel first and then working away from it.
• For a roof vent pipe over 3”(80mm) in diameter, the collectors can be positioned on either side of the vent.
Two 7” (18cm) System Connector Hoses (Part #60691-1 for 1 1/2” or #60691-2 for 2”) can be employed to
couple the collectors together for vent pipes or other obstacles up to 7” (18cm) in diameter. Mark your
51” (128cm) centers wherever the outlet header brackets ‘fall’ on the upper chalk line. With obstructions of
over 7”(18cm), such as attic fans and skylights, lay out the panels on either side of the obstructions using a
Row Spacer Kit (Part #12017-1 for 1 1/2”; #12017-2 for 2”) or Header Spacers.
• Refer to Figure 2 throughout this section.
Return to: Chapter 2 Home Page.
27
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step One: Outlet Header Bracket Location
Determine the position of the last Outlet Header Hold-Down Bracket for the row of collectors. Mark this point on
the roof. The Collector Outlet Headers will be located 1” (25mm) below this mark.
Refer to Figure 3.
F IGURE 3 Outlet Header Bracket Location
Return to: Chapter 2 Home Page.
28
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Two: Drill Along Chalkline
Using this point, snap a chalk line to the opposite end of the row. Slope this line down the roof toward the
inlet a minimum of 1/8” per foot.
Using a 1/8” (3mm) drill bit for 1/4” (6mm) diameter screws drill a hole for the first Outlet Header Bracket on the
first roof mark. Measure up 1” on center from the first pilot hole and drill pilot hole for second screw. Repeat this
process at 51” centers along the chalk line for the total number of collectors to be installed.
Return to: Chapter 2 Home Page.
29
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Three: Outlet Header Bracket Location
Inject a generous amount of high quality sealant into each hole and onto the surrounding roof surface. Bolt all the
outlet header Hold-Down Brackets to the roof as shown in Figure 4.
F IGURE 4 Outlet Header Bracket
Return to: Chapter 2 Home Page.
30
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Four: Hold-Down Strap Bracket Locations
Locate the Hold-Down Strap Bracket holes using the information in Table 2A shown below, (also shown in Figure
2 Table A). Measuring from the top outlet header bracket chalk line, snap another chalk line parallel to this line
using the “A” distance. The “B” distance is the same for all collector sizes, which is 16” (40cm) up from the
outside of the bottom header and can be measured after the collectors are installed. Wait to install the HoldDown Strap Brackets until after the collectors are installed so as not to damage the collectors when you are
bringing them to the roof for installation.
T ABLE 2 A Distance Between Panel Headers and Straps
COLLECTOR PANEL SIZE, FEET (M)
12 (3.6)
10 (3.0)
8 (2.4)
6 (1.8)
4 (1.2)
COLLECTOR (A) DISTANCE, INCHES (CM)
60 (152)
48 (122)
36 (91)
24 (60)
---
COLLECTOR (B) DISTANCE, INCHES (CM)
16 (40)
16 (40)
16 (40)
16 (40)
16 (40)
Return to: Chapter 2 Home Page.
31
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Five: Install Hose
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. Make sure that the header with the serial number label is used for the outlet or
top header with the serial number label facing downwards towards the mounting surface. The
System Connector Hoses (Part #60691-1 for 1 1/2”; # 60691-2 for 2”), go on the outlet of the last collector and the
inlet of the first collector. Place a Hose Clamp between the two indicator ridges on the hose, in order to center it
over the sealing groove in the header. This clamp must face up so as to be accessible for tightening and 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 BETWEEN THE TWO INDICATOR
RIDGES ON THE HOSE. DO NOT OVER TIGHTEN!
Refer also to Figure 2.
Return to: Chapter 2 Home Page.
32
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Six: Install Outlet Header Bracket with Hose
Position the collector on the roof so that the center of the outlet connection hoses are directly beneath the secured
outlet header brackets. Open the clamp that is part of the outlet header bracket, insert connection hose and
LIGHTLY TIGHTEN the clamp around the hose. Loosely place another clamp over the open end of the hose
before installing the next collector in the array. Refer to Figure 5. Continue to install all the collectors in the array,
coupling them side to side.
F IGURE 5 Installed Outlet Header Bracket with Hose
Return to: Chapter 2 Home Page.
33
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Seven: Header Clamp Assembly
If the Aluminum Header Clamp Assembly, Part #10117-1 for 1 1/2”; #10117-2 for 2”, or Outlet Header Clamp
Assembly, Part #10121 is to be used for supplemental mounting hardware, install them over the outlet header at
this time. Refer to Figure 6 or Figure 7.
F IGURE 6 Installed Aluminum Header Clamp Assembly
F IGURE 7 Installed Outlet Header Clamp Assembly
Return to: Chapter 2 Home Page.
34
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Eight: Install Hold-Down Strap Bracket
Proceed to the lower chalk line previously snapped on the roof for the Hold-Down Strap Brackets. Mark a hole
2” (5cm) to the side of the first collector and continue marking holes on the chalk line centered exactly between the
absorber surfaces until you reach the last collector. Mark the last hole the same 2” (5cm) to the side of the last
collector. Drill a pilot hole and apply sealant at each of these locations. Bolt the Hold-Down Strap Brackets on the
roof. Refer to Figure 8. Mark the holes for the bottom Hold-Down Strap by measuring up 16” (40cm)
from the outside of the bottom header and again centering them between the absorbers and 2” (5cm) away
from the first and last collector. It is OK to step on the collectors as long as you stay one foot away from the top and
bottom headers.
F IGURE 8 Strap Bracket
Return to: Chapter 2 Home Page.
35
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Nine: Install Strap
Slip a Strap Hold-Down Clamp over one end of the strap prior to sliding the strap through the slot of the Outlet
Header Bracket. Bend over approximately 3” of the strap (refer to Figure 9). Slide the Hold-Down Strap Clamp
towards the Outlet Header Bracket. Clamp screw should be tightened securely, but not over-tightened to the point
where the clamp is distorted. (refer to Figure 10) Bring the remaining strap end across the collector face, passing
through both slots in the bracket located on the other side of the collectors. (refer to Figure 11) Repeat strap
termination at opposite end*Pull the straps taut against the face of the collectors. Repeat this procedure for the
remaining Hold-Down Strap. *
Return to: Chapter 2 Home Page.
F IGURE 10 Outlet Header Bracket
F IGURE 9 Outlet Header Bracket
F IGURE 11
Strap Bracket
with Strap
36
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Ten: Install Vacuum Relief Valve
Install the Vacuum Relief Valve (Part #10003-1 for 1 1/2”; #10003-2 for 2”) in the outlet header of each row. This
will be located at the opposite end of the header that is connected to the collector return line. Refer to Figure 12.
DO NOT OVER TIGHTEN THE CLAMP!
Also, refer to Figure 2, Figure 14, Figure 15, and Figure 16.
F IGURE 12 Installed Vacuum Relief Valve
Return to: Chapter 2 Home Page.
37
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Eleven: Install End Cap
Install an End Cap, (Part # 30061-1 for 1 1/2”; #30061-2 for 2”) in the inlet header of each row, opposite the end
that is connected to the collector inlet pipe. Refer to Figure 13.
DO NOT OVER TIGHTEN THE CLAMP!
Also, refer to Figure 2, Figure 14, Figure 15, and Figure 16.
F IGURE 13 Installed End Cap
Return to: Chapter 2 Home Page.
38
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Step Twelve: Final Inspection
INSPECT THE INSTALLATION AND CHECK ALL CLAMPS FOR PROPER POSITION AND
TIGHTNESS.
Return to: Chapter 2 Home Page.
39
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Installation in High Wind Areas
When Installing in High Wind Areas it is recommended to use the Optional Supplemental High Wind Area
Collector Hold-Down Kit, Part #12035-1 for 1 1/2”; #12035-2 for 2”.
See Table 2B and Figure 17 for additional strap bracket locations.
T ABLE 2 C
See Table 2C for installation instructions.
TEMP
(°F)
T ABLE 2 B
COLLECTOR PANEL SIZE, FEET (M)
DIMENSION OF (A), INCHES (CM)
12 (3.6)
32 (81)
10 (3.0)
28 (71)
8 (2.4)
0
20 (51)
15
8’
5”
10’
5”
30
45
60
4- 3/4”
85
115
160
NOTE: Not at tension (at 75°F collector temperature)
4- 3/4”
4- 1/2”
130
145
5”
4- 3/4”
75
100
12’
4- 3/8”
4- 1/2”
4- 1/2”
4- 3/8”
4- 3/8”
Return to: Chapter 2 Home Page.
40
C HAPTER 2: M OUNTING THE S OLAR C OLLECTORS
Installation Over Roof Vent Pipes
• Collector models 10001 and 10204 with intermittent sonically welded plates can be installed over or around
different diameter roof vent pipes or other obstructions up to 2” (63mm) in diameter. After snapping the top
chalk lines but before marking and pre-drilling for your outlet header brackets, locate the seam in the collector
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 the vent pipe protrude near a sonic tack weld, it will have to be cut apart. Using a sharp utility
knife, cut through the weld while pulling the two plates apart. Lay the collector over the vent pipe, keeping the
vent pipe at least 12” (30.5cm) away from a header. It will be easier to complete an installation by mounting this
collector first and then working away from it.
• If you have the installation flexibility it is easier to locate vent pipes up to 2” between adjacent collectors.
• With a roof vent pipe of 3” (8cm) in diameter, the collectors can be positioned on either side of the vent. Two
System Connector Hoses (Part #60691-1 for 1 1/2”; # 60691-2 for 2”) can be employed to couple the collectors
together for vent pipes or other obstacles up to 7” (17cm) in diameter. Mark your 51” (1.3m) centers wherever the
outlet header brackets ‘fall’ on the upper chalk line.
• With obstructions of over 7” (17cm), such as attic fans and skylights, lay out the collectors on either side of the
obstruction using a Row Spacer Kit (Part #12017-1 for 1 1/2”; #12017-2 for 2”) or Header Spacers.
See Diagram or refer to Figure 18 .
Return to: Chapter 2 Home Page.
41
C HAPTER 3
System Piping
C HAPTER 3: S YSTEM P IPING
Contents
*. Overview
1. Flow Rate
2. Reverse Return
3. Direct Return
4. Optional Isolation Valves
5. Collector By-Pass Check Valve
6. Special System Layouts
7. System Below Pool Level
43
C HAPTER 3: S YSTEM P IPING
Overview
• 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. (For other
types please contact factory)
If a fuel-fired heater or heat pump is installed, it is located between the collector return line 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.
• Whenever there is more than 50 gpm (189L) required flow rate to the collectors or more than 100’ (30m) of
piping used in a system, install 2” (63mm) piping to and from the collectors. (See Table 3A for Pipe Size based on
Flow Rate.) 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.
• 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.
• Use a PVC cutter or a PVC wide-blade saw (not a hacksaw) for cutting pipe. It is important to use both a 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.
• Piping should also be supported at intervals based on pipe size. (See Table 3A.) Aquatherm Industries Pipe
Brackets made from high-strength glass-reinforced polypropylene are available in 1 1/2” (Part #30272-1 black;
#30284-1 white) and 2” (Part #30272-2 black; #30284-2 white).
Refer to Figure 14, Figure 15, and Figure 16 throughout this section.
Return to: Chapter 3 Home Page.
44
C HAPTER 3: S YSTEM P IPING
System Piping Overview Cont.
T ABLE 3 A
MINIMUM FLOW TO PURGE AIR
SUPPORT CENTERS FOR
HORIZONTAL PVC PIPE
(FEET) @100ºF
MIN. PIPE
SIZE @ 7FT/S
VELOCITY
(INCHES)
FLOW-UP
HORIZONTAL
FLOW
DOWN FLOW
2 FT/S
4 FT/S
6 FT/S
SDR&SCH. 40
SCH. 80
40
1-1/2
11
22
33
5
5-1/2
80
2
20
39
59
5
6
115
2-1/2
31
61
92
5-1/2
6-1/2
160
3
44
88
132
6
7
300
4
78
157
235
6-1/2
7-1/2
650
6
176
353
529
7-1/2
9
1050
8
300
650
1000
8
9-1/2
FLOW
RATE
(GPM)
Note: Where Pipe sizes are not available or total pipe run exceeds 100ft, use the next larger size pipe.
Return to: System Piping Overview.
44
45
C HAPTER 3: S YSTEM P IPING
Flow Rate
• In order to receive optimum performance from Aquatherm Industries collectors, the following recommended
flow rates and number of collectors per row should be followed. When the system is running, all the collectors
should feel uniformly cool to the touch, and there should be no residual air left in the pool return lines. If either
of these two conditions persist, chances are that the flow rates thru the collectors are inadequate or the system is
not properly balanced. A flow meter can be installed in the collector feed line to check on the flow rate. If the flow
rates are within the limits as shown below in Table 3B, then the system may not be properly balanced, especially
with systems requiring multiple banks of collectors. Refer to Special System Layouts.
• If the flow rate is below the minimum as shown in the table above, then the pool pump size or pipe size should be
increased, or a booster pump installed in some cases. If the flow rate is excessive (more than 10 GPM/(37.9l )
collector), or if the system pressure is greater than 30 psi, a by-pass Check Valve (Refer to Figure 14A) should be
installed between the collector feed and return lines above the 3-way valve to prevent problems with the
collectors and connection hoses.
• If there is residual air in the pool return lines and the collectors do feel cool to the touch, refer to the section
concerning the Vacuum Relief Valve Test (Chapter 6 Section 3.)
T ABLE 3 B
COLLECTOR SIZE, FEET:
4 X 12
4 X 10
4X8
STANDARD FLOW RATE PER COLLECTOR, GPM (LTR/MIN)
5.0 (18.9)
4.0 (15.1)
3.25 (12.5)
MINIMUM FLOW RATE PER COLLECTOR, GPM (LTR/MIN)
3.0 (11.4)
2.5 (9.5)
2.5 (9.5)
10; 12
12; 12
12; 14
480; 576
480; 576
480; 576
[email protected];
0.05 @2.5
[email protected];
[email protected]
[email protected];
[email protected]
MAXIMUM # COLLECTORS PER ROW, 1 1/2”; 2”
MAXIMUM SQUARE FOOTAGE PER ARRAY, 1 1/2”; 2”
PRESSURE DROP, [email protected]: 1 1/2”;
2”
Return to: Chapter 3 Home Page.
46
C HAPTER 3: S YSTEM P IPING
Reverse Return
Refer to Figure 19.
F IGURE 19 Reverse Return
Return to: Chapter 3 Home Page.
47
C HAPTER 3: S YSTEM P IPING
Direct Return
F IGURE 20 Direct Return
Refer to Figure 20.
T ABLE 3 C Number of Recommended Collectors to Use in a Direct Return System
COLLECTOR SIZE:
8’
10’
12’
1 1/2”
2”
1 1/2”
2”
1 1/2”
2”
MINIMUM FLOW RATE (0.06 GPM/FT²)
-
-
-
-
-
-
STANDARD FLOW RATE, (0.10 GPM/FT²)
6
6
6
6
6
6
RECOMMENDED FLOW RATE, (0.15 GPM/FT²)
7
8
7
8
7
7
MAXIMUM FLOW RATE, (10 GPM PER COLLECTOR)
8
12
8
10
8
8
Return to: Chapter 3 Home Page.
48
C HAPTER 3: S YSTEM P IPING
Optional Isolation Valves
• Isolation valves may be installed in the collector 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 collector inlet line and a
check valve on the collector return line. Both valves, available in the Optional Supplemental System Isolation Kit
(Part #12033-5) are made to accept either 1 1/2” or 2” PVC pipe. 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 close to the control valve
and outlet ‘T’, respectively.
• For further precautions in warm climates where pools are operated year round and periodic freezes can occur, a
bypass line (small diameter tubing) can be located above the ball and check valve so as to prevent any accidental
trapping of water in the collectors by the pool owner. To make sure no water is left in the collectors for servicing
or during freezing conditions, remember that the pool pump should be shut off, allowing the collectors to drain
naturally, before the optional isolation valves are used.
• If the system is installed on a commercial or public pool, local codes may require positive isolation valves in the
collector feed and return lines. See Figure 18 A for the proper placement of the isolation check valve and pressure
relief valve.
Return to: Chapter 3 Home Page.
49
C HAPTER 3: S YSTEM P IPING
Collector By-Pass Check Valve
At high flow rates above the collector’s recommendation, the valve opens to by-pass the water and only send the
recommended flow rate to the system. This is to relieve stresses on the collector system, the system pump, along
with preventing filtration issues.
The Check Valve (Part #60717) comes as a 1/2 lb system check valve. It also comes with a 6 lb spring for a single
story building and a 10 lb spring for two story buildings.
See tables below for what spring to use for various flow rates.
Refer to Figure 14 A.
T ABLE 3 D 6 lb Spring
T ABLE 3 E 10 lb Spring
GPM FROM PUMP GPM TO SYSTEM GPM BY-PASSED
GPM FROM PUMP GPM TO SYSTEM GPM BY-PASSED
40
25
15
40
36
4
50
35
15
50
38
12
60
41
19
60
39
21
70
47
23
70
42
28
80
57
23
80
46
34
90
65
25
90
48
42
100
72
28
100
50
50
Return to: Chapter 3 Home Page.
50
C HAPTER 3: S YSTEM P IPING
Special System Layouts
• 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 is non-uniform, the heating capacity of the system
will be reduced.
• WHEN INSTALLING A DIVIDED SYSTEM, THE OUTLET HEADERS FROM EACH OF THE
LOWER (OR CLOSEST) ROWS OF COLLECTORS MUST BE CONNECTED TO THE HIGHEST (OR
FURTHEST) POINT IN THE SYSTEM.
Refer to Figure 16
• A divided system requires an Add-A-Row Kit (Part #12043-1 for 1 1/2”; #12043-2 for 2”) for each additional row
of collectors. This also illustrates the application of the Row Spacer Kit (Part # 12017-1 for 1 1/2”; #12017-2 for
2”) or Header Spacers to clear a roof obstruction.
Return to: Chapter 3 Home Page; Chapter 3-Section 2: Flow Rate.
51
C HAPTER 3: S YSTEM P IPING
System Below Pool Level
If the collectors are to be installed below the level of the pool, isolation ball valves and a manual drain should be
installed. If the system requires the use of a booster pump, it should be located on the return line from the
collectors. Refer to Figure 21.
For systems installed below pool level with a booster pump, a swing-type check valve may be used instead of a 3way motorized value. Refer to Figure 21A.
F IGURE 21 System Below Pool Level with 3-way Valve
Figure 21A System Below Pool Level without 3-way Valve
Return to: Chapter 3 Home Page.
52
C HAPTER 4
Control Systems
C HAPTER 4: C ONTROL S YSTEMS
Contents
1.Manual System
2.Automatic Control System
3.Booster Pump System
54
C HAPTER 4: C ONTROL S YSTEMS
Manual System
• Some systems employ a manual control valve to divert the flow of water thru the solar collectors, though this may
reduce the overall heating capacity of the system. A manual control valve usually consists of a non-positively
sealed 3-way valve used in place of the motorized valve as shown in Figure 14 Water continuously flows through
the solar collectors when the filter pump is on, but can be diverted manually by the pool owner 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 3-way manual valve to
the “bypass collector” position and shutting the isolation valve on the collector feed line. 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
collectors. The filter pump can then be restarted to allow for normal pool filtration.
Refer to Figure 15.
Refer to Manual Systems Start-Up.
Return to: Chapter 4 Home Page.
55
C HAPTER 4: C ONTROL S YSTEMS
Automatic Control System
• The performance of a solar pool heating system can be maximized with the use of an electronic control and
motorized 3-way valve. The control activates the motorized valve and either sends water thru the 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
control you use.
• During normal operation of the system when the 3-way valve is in the ‘bypass collector’ position all the water in
the collectors should drain back through the 3-way 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”,
3-6mm) between the collector feed and return line above the isolation valves, if any. It is possible that a small
amount of water may be present in the collectors when a non-positively sealed 3-way valve is used and the filter
pump is on. If a positively sealed 3-way valve is used, a bypass line as mentioned above is mandatory to allow for
collector drainage.
Refer to Figure 14.
Refer to Automatic Control Systems Start-Up.
Return to: Chapter 4 Home Page.
56
C HAPTER 4: C ONTROL S YSTEMS
Booster Pump System
Booster Pump System
• In some cases, the pool filtration pump may not be able to circulate water at a high enough flow rate to allow for
proper collector 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 to one with greater flow
ratings.
Refer to Figure 18, Figure 21, and Figure 21A.
• If the system is installed on a commercial or public pool, local codes may require positive isolation valves in the
collector feed and return lines. See Figure 18 A for the proper placement of the isolation check valve and pressure
relief valve.
Return to: Chapter 4 Home Page.
57
C HAPTER 5
Other Equipment
C HAPTER 5: O THER E QUIPMENT
Contents
1.Pool Cleaners
2.Chlorinators/ Salt Generators
3.Supplemental Heaters
59
C HAPTER 5: O THER E QUIPMENT
Pool Cleaners
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 unless the control system has a cleaner time delay.
Refer to Figure 14B.
F IGURE 14 B Location of Pool Cleaners
Return to: Chapter 5 Home Page.
60
C HAPTER 5: O THER E QUIPMENT
Chlorinators/Salt Generators
If the pool uses an automatic chlorinator, this should be plumbed after the outlet tee on the return to the pool.
Refer to Figure 14 C.
F IGURE 14 C Location of Chlorinator and Salt Generator
Return to: Chapter 5 Home Page.
61
C HAPTER 5: O THER E QUIPMENT
Supplemental Heaters
Supplemental Gas, Oil-Fired, or Electric Heaters
• It is desirable to pipe the standby heater in a bypass loop. Refer to Figure 14, Figure 15, or Figure 17. Fuel-fired
heaters often create a large pressure drop. By placing a heater in a bypass loop, pump size, and electrical energy
requirements may be reduced.
Refer to Figure 14D.
F IGURE 14D Location of Supplemental Heater
Return to: Chapter 5 Home Page.
62
C HAPTER 6
System Start-Up, Testing,
and Troubleshooting
C HAPTER 6: S YSTEM S TART -U P , T ESTING , AND T ROUBLESHOOTING
Contents
1.Checking for Operation
2.Manual Control Systems
3.Automatic Control Systems
4.Vacuum Relief Valve Test
5.Flow Rates Test Methods
64
C HAPTER 6: S YSTEM S TART -U P , T ESTING , AND T ROUBLESHOOTING
Checking for Operations
Each time the solar system cycles on, there are a few things to watch for:
1) Air will initially be purged into the pool. This may last several minutes.
2) The filter pressure will increase slightly and remain elevated as long as pool water is flowing through the
solar collector.
3) When the system is running, all the collectors should feel uniformly cool to the touch.
Return to: Chapter 6 Home Page.
65
C HAPTER 6: S YSTEM S TART -U P , T ESTING , AND T ROUBLESHOOTING
Manual Control Systems
• To test collector operation, follow either the flow-rate or temperature-rise procedure. Divert water through the
collectors. Turn on the pump and either observe flow rate or temperature rise. The flow rate or temperature rise
would be the same as that specified in the “System Start-Up and Test” section. If it is not, then check for the
indicated probable causes and make necessary corrections.
Refer to Manual Control Systems Overview.
Return to: Chapter 6 Home Page.
66
C HAPTER 6: S YSTEM S TART -U P , T ESTING , AND T ROUBLESHOOTING
Automatic Control Systems
• To check out an automatic system for proper operation turn on the filter system. Set the temperature control to
its highest level. Switch the control to the “Manual ON” mode. The “Heating” or “Solar ON” light should come on.
The 3 way 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 collectors should feel uniformly cool to the touch.
Switch the control to the “Manual OFF” mode. The corresponding light will go off and the 3 way valve will be
sending water directly back to the pool, bypassing the solar collectors. After about 5-10 minutes, feel the solar
collectors again. They should have begun to warm up. Now switch to “Auto” or “Solar Enabled”. If the sun is still
shining on the solar collectors, the “Heating” or “Solar ON” light should go on again. Adjust the temperature
control lower.
• When you reach the actual temperature of the pool water, the light will turn off. The “Heating” or “Solar ON”
light will go off again. Move the temperature control to the desired comfort level. The “Heating” or “Solar ON”
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.
Refer to Automatic Control System Overview.
Return to: Chapter 6 Home Page.
67
C HAPTER 6: S YSTEM S TART -U P , T ESTING , AND T ROUBLESHOOTING
Vacuum Relief Valve Test
• When the solar system is first turned on, air in the collectors will be expelled into the pool and bubbles will
appear. The appearance of bubbles in the pool should stop after a few minutes.
• 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 a Vacuum Relief Valve to a position in the inlet piping which is
at a height of approximately 3/4 of the elevation of the collectors above the pool. Refer to Figure 2.
• 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.
Return to: Chapter 3-Section 2: Flow Rate; Chapter 6 Home Page.
68
C HAPTER 6: S YSTEM S TART -U P , T ESTING , AND T ROUBLESHOOTING
Flow Rates Test Methods
1. Touch Method
• 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 this optimum performance condition will now
exist. 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.
2.Flowmeter
• The preferred system test method is flow rate. This is also the easiest and quickest method. To check flow rate,
install a flow meter in the inlet line to the collectors (follow installation instructions provided with the
flowmeter).
Return to : Chapter 6 Home Page.
69
C HAPTER 6: S YSTEM S TART -U P , T ESTING , AND T ROUBLESHOOTING
Flow Rates Test Methods Cont.
3. Temperature Rise Test Method
• An alternate test method is temperature rise. To prepare the system for testing, obtain two accurate
thermometers. One of these thermometers is installed in the outlet line from the collectors as shown in
Figure 14. 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
thermometers 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 you are testing. This is necessary in order to provide an accurate indication of the
temperature rise of the water passing through the solar collectors.
• Turn the pump on and move the flow switch to the “Manual ON” position. Observe valve action...it should
divert water through the collectors. After flow through the collectors has continued for a 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 70°F (40°C) the water leaving the
collectors should be 1° to 7°F (1° to 4°C) higher than that in the pool. If the water rise is greater than this,
insufficient water is flowing through the collectors. This may be caused by a clogged filter, undersized
piping, to 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.
Return to: Chapter 6 Home Page.
70
70
C HAPTER 7
Maintenance
C HAPTER 7: M AINTENANCE
Contents
1. Pool Service and Maintenance
2. Cold Weather Operation/ Winterizing Procedures
3. Annual Inspection
72
C HAPTER 7: M AINTENANCE
Pool Service and Maintenance
It is advisable to bypass the solar collectors when either backwashing your filter or adding Diatomaceous Earth
(DE). This prevents the possibility of any DE or other debris from passing through the solar system as well as any
other pool equipment downstream of the filter. When the backwashing cycle and/or the adding of DE is complete,
run the filtration system for 10-15 minutes before returning your solar heating system to operation. If you have an
automatic pool cleaning system with its own pump, there may be several precautions that you need to take
depending on what type of system you have. These precautions prevent the air that is initially purged from the
solar system from possibly damaging pool cleaning equipment during the turning on cycle of your solar system.
Manual Control- do not start the flow of water through the solar collectors while the pool cleaning pump is
running. Allow the air to be purged from the system and then activate your pool cleaning system.
Automatic Systems- if your automatic control system is not equipped with a timed pool cleaner delay cycle, it
will be necessary to run your pool cleaner in the early morning and turn it off before your solar system comes on
or turn it on in the late morning, well after your solar system normally cycles on. If you manually vacuum your
pool, bypassing the solar collectors at this time will provide you with full power for better vacuuming
performance.
Return to: Chapter 7 Home Page; Annual Inspection.
73
C HAPTER 7: M AINTENANCE
Cold Weather Operation/Winterizing Procedures
• If installed according to this manual, 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 some areas, pool owners operate their pools throughout the winter although light freezing conditions may
occur. If the system can not be drained and isolated, the accepted procedure for avoiding freezing of the pool
piping and filtration system has been to continuously circulate the water.
When solar heaters are used on a pool under these conditions, anti-freeze precautions should be taken. In order
to protect the collectors as well as appurtenant components such as End Caps and pipe fittings and against
unusual or severe freezing conditions, one of the following two procedures should be followed when freezing
weather is imminent.
1. Turn circulating system off and allow solar collectors and piping to drain. Isolate collectors with gate or ball
valve in collector feed line and a check valve in the collector return line. Switch the solar control to “OFF” or
“Solar Disabled”. The pool filtering system may then be turned back on. When freezing conditions have
passed, open isolation valve(s) and switch the solar control to “AUTO” or “Solar Enabled”.
2. If isolation valves are not installed in the system, switch the solar control to the “Manual ON” position so
that water circulates through the collectors. When freezing conditions have passed, switch the solar control
to “AUTO” or “Solar Enabled”. THIS METHOD IS NOT RECOMMENDED WHERE
TEMPERATURE LEVELS MAY DROP SEVERELY.
Return to: Chapter 7 Home Page.
74
C HAPTER 7: M AINTENANCE
Annual Inspection
Annual Service Collector 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. In areas where unusually
high stagnation temperatures are prevalent or where abnormally high system pressures occur, use Header
Insert (Part #50055-1 for 1 1/2”; # 50055-2 for 2”).
Note: Also see Pool Service and Maintenance.
Return to: Chapter 7 Home Page.
75
C HAPTER 8
Collector Repair
C HAPTER 8: C OLLECTOR R EPAIR
Contents
1. Repair Plug
2. Screw Method
77
C HAPTER 8: C OLLECTOR R EPAIR
Repair Plug
The following instructions are for using Collector Repair Plug, Part # 30143, in order to stop a leak in a collector.
Each leaking tube will require two plugs.
• Locate the leak and mark the tube to be plugged.
• With the pump turned off; using a sharp cutting tool, cut a 1” section out of the tube approximately 2” away
from the header. Repeat on the opposite side of the tube. NOTE: CUT AWAY FROM THE HEADER
REMOVING THE TOP HALF OF THE TUBE. BE CAREFUL NOT TO CUT ADJACENT TUBES.
• Wet the cut out area of the tube and the plug with water. DO NOT USE A LUBRICANT.
• Insert the plug towards the header, narrow side first, use a #0 Phillips Head Screwdriver to completely insert
the plug into the tube. Remove Screw Driver with a twisting motion. Repeat this process with the second plug
on the opposite side of the collector.
• After both plugs have been inserted; test that a seal had been achieved by turning the system on.
Return to: Chapter 8 Home Page.
78
C HAPTER 8: C OLLECTOR R EPAIR
Screw Method
This method allows for an easy and permanent on site repair of a collector 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.
• 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. This repair method will not void the collector
warranty.
Refer to Figure 22.
Return to: Chapter 8 Home Page.
79
C HAPTER 9
Appendix
C HAPTER 9: A PPENDIX
Contents
Figure 1: Mounting Components Diagram
Figure 2: Assembly on Roof Diagram
Figure 3: Outlet Header Bracket Location
Figure 4: Outlet Header Bracket
Figure 5: Installed Outlet Header Bracket with
Hose
Figure 6: Installed Aluminum Header Clamp
Assembly
Figure 7: Installed Outlet Header Clamp
Assembly
Figure 8: Strap Bracket
Figure 9: Outlet Header Bracket
Figure 10: Outlet Header Bracket
Figure 11: Strap Bracket with Strap
Figure 12: Installed Vacuum Relief Valve
Figure 13: Installed End Cap
Figure 14: Automatic Plumbing System
Schematic
Figure 14A: Location of Collector By-Pass Check
Valve
Figure 14B: Location of Pool Cleaner
Figure 14C: Location of Chlorinator and Salt
Generator
Figure 14D: Location of Supplemental Heater
Figure 15: Manual Plumbing System Schematic
Figure 16: Multiple Arrays Plumbed in Parallel
Figure 17: High Wind Area Additional Strap
Bracket Locations
Figure 18: Booster Pump System for Outdoor
Pools
Figure 18A: Location of Optional Isolation Valves
Figure 19: Reverse Return
Figure 20: Direct Return
Figure 21: System Below Pool Level with 3-way
Valve.
Figure 21A: System Below Pool Level without 3way Valve.
Figure 22: Collector Repair
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Figure 1: Mounting Components Diagram
F IGURE 1 Mounting Components Diagram
Return to: Appendix Contents.
82
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Figure 2: Assembly on Roof Diagram
F IGURE 2 Assembly on Roof Diagram
Return to: Mounting the Solar Collectors Overview; Step Four; Step Five; Step Ten;
Step Eleven; Vacuum Relief Valve Test; Appendix Contents.
83
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Figure 3: Outlet Header Bracket Location
F IGURE 3 Outlet Header Bracket Location
Return to: Step One; Appendix Contents.
84
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Figure 4: Outlet Header Bracket
F IGURE 4 Outlet Header Bracket
Return to: Step Three; Appendix Contents.
85
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Figure 5: Installed Outlet Header Bracket with Hose
F IGURE 5 Installed Outlet Header Bracket with Hose
Return to: Step Six; Appendix Contents.
86
C HAPTER 9: A PPENDIX
Figure 6: Installed Aluminum Header Clamp Assembly
F IGURE 6 Installed Aluminum Header Clamp Assembly
Return to: Step Seven; Appendix Contents.
87
C HAPTER 9: A PPENDIX
Figure 7: Installed Outlet Header Clamp Assembly
F IGURE 7 Installed Outlet Header Clamp Assembly
Return to: Step Seven; Appendix Contents.
88
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Figure 8: Hold-Down Strap Bracket
F IGURE 8 Hold-Down Strap Bracket
Return to: Step Eight; Appendix Contents.
89
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Figure 9: Outlet Header Bracket
F IGURE 9 Outlet Header Bracket
Return to: Step Nine; Appendix Contents.
90
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Figure 10: Outlet Header Bracket
F IGURE 10 Outlet Header Bracket
Return to: Step Nine; Appendix Contents.
91
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Figure 11: Strap Bracket with Strap
F IGURE 11 Strap Bracket with Strap
Return to: Step Nine; Appendix Contents.
92
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Figure 12: Installed Vacuum Relief Valve
F IGURE 12 Installed Vacuum Relief Valve
Return to: Step Ten; Appendix Contents.
93
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Figure 13: Installed End Cap
F IGURE 13 Installed End Cap
Return to: Step Eleven; Appendix Contents.
94
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Figure 14: Automatic Plumbing System Schematic
F IGURE 14 Automatic Plumbing System Schematic
Return to: Step Ten; Step Eleven; System Piping; Manual Systems; Automatic Systems;
Supplemental Heaters; Flow Rates Test Methods Cont.; Appendix Contents.
95
C HAPTER 9: A PPENDIX
Figure 14 A: Location of Collector By-Pass Check Valve
F IGURE 14 A Location of Collector By-Pass Check Valve
Return to: Flow Rate; Collector By-Pass Valve; Appendix Contents.
96
C HAPTER 9: A PPENDIX
Figure 14 B: Location of Pool Cleaners
F IGURE 14 B Location of Pool Cleaners
Return to: Pool Cleaners; Appendix Contents.
97
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Figure 14 C: Location of Chlorinators and Salt Generators
F IGURE 14 C Location of Chlorinators and Salt Generators
Return to: Chlorinators/Salt Generators; Appendix Contents.
98
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Figure 14 D: Location of Supplemental Heater
F IGURE 14 D Location of Supplemental Heater
Return to: Supplemental Heaters; Appendix Contents.
99
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Figure 15: Manual Plumbing System Schematic
F IGURE 15 Manual Plumbing System Schematic
Return to: Step Ten; Step Eleven; System Piping; Manual Systems;
Supplemental Heaters; Appendix Contents.
100
C HAPTER 9: A PPENDIX
Figure 16: Multiple Arrays Plumbed in Parallel
F IGURE 16 Multiple Arrays Plumbed in Parallel
Return to: Step Ten; Step Eleven; System Piping; Special System Layouts; Appendix Contents.
101
C HAPTER 9: A PPENDIX
Figure 17: High Wind Area Additional Strap Bracket Locations
F IGURE 17 High Wind Area Additional Strap Bracket Locations
Return to: Installation in High Wind Areas; Appendix Contents.
102
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Figure 18: Booster Pump System Diagram for Outdoor Pools
F IGURE 18 Booster Pump System Diagram for Outdoor Pools
Return to:Installation Over Roof Vent Pipes; Booster Pump Systems;
Supplemental Heaters; Appendix Contents.
103
C HAPTER 9: A PPENDIX
Figure 18 A: Location of Optional Isolation Valves
F IGURE 18 A Location of Optional Isolation Valves
Return to: Optional Isolation Valves; Booster Pump System; Appendix Contents.
104
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Figure 19: Reverse Return
F IGURE 19 Reverse Return
Return to: Reverse Return; Appendix Contents.
105
C HAPTER 9: A PPENDIX
Figure 20: Direct Return
F IGURE 20 Direct Return
Return to: Direct Return; Appendix Contents.
106
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Figure 21: System Below Pool Level with 3-way Valve
F IGURE 21 System Below Pool Level with 3-way Valve
Return to: System Below Pool Level; Booster Pump System; Appendix Contents.
107
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Figure 21A: System Below Pool Level without 3-way Valve
F IGURE 21 A System Below Pool Level without 3-way Valve
Return to: System Below Pool Level; Booster Pump System; Appendix Contents.
108
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Figure 22: Collector Repair
F IGURE 22 Collector Repair
Return to: Screw Method; Appendix Contents.
109
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