Boss Solar PROSOLAR User manual

Boss Solar Strip Thermal Solar Pool Heating | INSTALLATION MANUAL
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Revision: C
Revision Date: 18/11/2021
TABLE OF CONTENTS
INTRODUCTION..............................................................................................................................2
PURPOSE AND SCOPE...................................................................................................2
SAFETY PRECAUTIONS .................................................................................................2
BEFORE YOU START - LOCATION ADVICE:.................................................................2
HOW IT WORKS...............................................................................................................3
REQUIRED TOOLS..........................................................................................................3
INSTALLING THE SYSTEM..........................................................................................................4
SYSTEM CONFIGURATION......................................................................................................4
MANIFOLD INSTALLATION ......................................................................................................5
SOLAR COLLECTOR COIL INSTALLATION..........................................................................7
ANCILLERY INSTALLATION.....................................................................................................8
PLUMB THE SYSTEM TO THE PUMP HOUSE ...............................................................9
Independent / Separate Suction System..................................................................................9
Simultaneous / Integrated / Retro Fit Configuration..............................................................10
Manual System (No Pump or Digital Controller) ...................................................................11
TROUBLESHOOTING RETURN SYSTEM PRESSURE................................................... 12
SERVICE AND MAINTENANCE SCHEDULE ................................................................13

Boss Solar Strip Thermal Solar Pool Heating | INSTALLATION MANUAL
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Revision: C
Revision Date: 18/11/2021
INTRODUCTION
PURPOSE AND SCOPE
The intent of this installation guide is to equip the reader with sufficient knowledge to design and install a Boss
ProSolar or Ultimate Blue Solar System. To ensure that the Systems and Components function and perform
correctly, all recommendations presented in this manual should be adopted by the reader; failure to do so may
void the warranty. This installation guide is for domestic installations only.
SAFETY PRECAUTIONS
When installing a solar system, always exercise extreme caution when working with heights or around water; do
not use short cuts, as there is no substitute for safety. The installer of any Boss Solar Pool Heating System (or
component) must accept responsibility for assessing and implementing safety systems and procedures in
accordance with all regulatory and moral requirements. The potential to fall from a roof is a major risk along with
electric shock and exposure to harmful U.V. radiation and heat exhaustion. It is expected that the reader installing
the system uses all necessary safety harnessing, scaffolding, safety railing and suitable footwear. It is also
expected that the reader is aware of any electrical shock hazards, weather conditions, the roof condition, roof
access methods, pitch angle, and sun protection when deciding to install the system.
For more information on working safely with heights, check out the Work Safe ‘Working with Heights’ website for
more information http://www.worksafe.vic.gov.au/safety-and-prevention/small-business/12-ways-to-make-small-
businesses-safer/working-at-heights
BEFORE YOU START - LOCATION ADVICE:
It’s important you select a suitable roof to ensure optimum performance of your new thermal solar system. Take
care to select a roof with no shading from neighbouring buildings or vegetation.
The optimum position to install a thermal solar pool heating system is on a Northwest, North, flat (15° or less), or
West facing roof. A system can be installed on an East facing roof, however a slight increase in on coverage is
recommended. Approximately 6%.
It is not recommended to install a solar system on a South facing roof.

Boss Solar Strip Thermal Solar Pool Heating | INSTALLATION MANUAL
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HOW IT WORKS
The pool is heated by circulating water through the thermal solar pool heating collectors which are mounted to
the roof of a building. The solar collectors absorb the sun’s heat and transfer it to the pool water. The heated
water is then returned to the pool. Most solar systems include a separate pump and automatic solar controller to
maximise heating efficiency and control. Thermal Solar Pool Heating systems can be fitted to either new or
existing pools.
REQUIRED TOOLS
Standard Chalking
Gun
Impact Driver or Drill
Philips Head Bit
Type ‘P’ PVC
Cement & Primer
2 x Shifter or
14 A/F & 16 A/F
Spanner
8.5mm Drill Bit

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INSTALLING THE SYSTEM
SYSTEM CONFIGURATION
Review the below solar configurations and select the system that will best suit your roof shape.
All systems must be plumbed with a feed header, return header and a balance pipe to ensure complete and even
water flow throughout the collector.
Bottom Feed Loop Return
This plumbing configuration provides:
•Even water flow throughout the collector
when the pump is switched on, and
•swift and efficient drain down back to the
pool when the pump is switched off
•Configuration can be installed over multiple
roof faces
Depending on the roof shape and size, the
installer has the choice to install the Bottom
Feed Solar System in several different
configurations:
This configuration should be adopted
wherever possible.
Bottom Feed System –“U” Loop Configuration
Bottom Feed Butterfly
This plumbing configuration provides:
•Swift and efficient drain down back to
the pool when the pump is switched
off
•Efficient use of available roof space
on triangular or odd shaped roofs
•Configuration can be installed over
multiple roof faces
Note: Configurations with varying loop run
lengths may result in reduced system
efficiency and performance
Bottom Feed System –Butterfly Configuration
Bottom Feed System –Butterfly Configuration
Multiple roof surfaces

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MANIFOLD INSTALLATION
STEP 1: Taking note of which pipe is flow and return,
complete the PVC pipework from the gutter up, utilising
40mm PVC pressure pipe.
The FLOW pipe (Water to Roof) will require a 45° elbow and
Vacrel installed at the very top of the system.
The RETURN pipe (Water to Pool) requires two 90° elbows
and one end cap at the very bottom of the system.
METAL ROOF
Each EzyClip is supplied with two screws, which are installed
at opposite corners of the clip.
Mark the corners where you wish to install the screws and
apply a bead of silicone to the roof. Place the EzyClip on top
and fix using the two supplied screws. Snap the PVC
manifold system into place.
TILE ROOF
Lift the tile and slide the EzyTie underneath until it hooks
onto the below tile. For extra security you may wish to apply
a bead of silicone before releasing the tile. Lay the PVC Pipe
over the top. If there is excess rubber, fold the EzyTie back
on itself and rest the PVC manifold on top. Slide the supplied
UV Resistant cable tie into the appropriate hole. Loop the
cable tie around the pipe and tighten until firm. Do not over
tighten. Trim excess cable tie with side cutters or scissors.
Ensure the pipework is securely fixed to the roof using the mounting system that matches your roof type

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STEP 2: Starting at the top of the manifold system on the
FLOW pipe, work out the position of the first collector run.
Mark the position of the first Tufman 10-1 manifold.
Using the supplied counterbore tool in your kit, drill a hole.
Ensure the hole is clean and free of swarm and burrs.
STEP 3: Using the supplied silicone lubricant, lubricate the
10-1 Manifold grommet.
*Be wary of overspray, slip hazard*
Push the grommet into the drilled hole until it is seated and
locked into position.
STEP 4: Push the Tufman 10-1 manifold into the grommet
until it is firmly seated.
Loop one of the supplied cable ties through 2 holes and
secure around the PVC pipe, tighten until firm.
All holes should be drilled along a neat, straight line.
You may wish to draw a line on the pipe before drilling

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SOLAR COLLECTOR COIL INSTALLATION
STEP 1: Beginning with one end of the collector only,
strip and remove the connecting web between the
collector tubes back by approximately 150mm.
*Pointy nose pliers can assist with this step*
Trim the webbing back using a pair of scissors
Lubricate both the inner and outer surface of the tubes
and then slide 10 collars over each tube, making sure the
lip of the collar is towards the end of the strip.
*Be wary of overspray, slip hazard*
STEP 2: Push each tube onto the appropriate barb,
leaving approximately 4-5mm gap between the manifold
body and end of tube.
Using a pair of multigrips, push each collar onto the
manifold, this will securely lock each barb into place.
STEP 3: Lay the coil in a straight line to the designated strip length. It may be useful to have a reference line
marked to guarantee the strips are in a straight line. Once the desired length is reached, lead the coil around
(do not flip) and continue unrolling back towards the manifold system.
STEP 4: Using the solar collector as a guide, mark the position of the Tufman 10-1 manifold in the RETURN
pipe, following the steps outlined above, drill and install the manifold.
If required, trim the collector to length using a sharp pair of scisors.
Using the steps above, remove the web, lube, collar and connect the solar to the manifold system.
STEP 5: Repeat the process until 2 strips of solar
collector and manifolds have been installed.
Adjust the two connected strips so they are straight and
neat. Once satisfied, apply a generous line of Prosil 60
Black silicone adhesive under the solar strips with a
caulking gun, apply at 400mm to 500mm intervals.
Press the solar down firmly to ensure a good bond.
*Do not use any adhesive other than the Prosil product
provided - untested silicones can have negative effects on
the solar collector*
STEP 6: Repeat this process of laying, connecting, and gluing the collector at two strips at a time until all
collector is installed.

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ANCILLERY INSTALLATION
Drain Down Tube
The Drain Tube allows the supply pipe to slowly drain
back via the return pipe when the pump is switched
off.
To install, mark a location on both the supply and
return pipework, approximately 1 –1.5m above the
pump level against the wall. Drill 8.5mm holes in the
pipes, using an 8.5mm Drill Bit.
It is highly recommended that you drill a small pilot
hole first, then drill the holes by running the drill in
reverse to minimise the risk of pipe shatter. Using a
blunted drill bit is also preferable. Clean the drill swarf
and burrs.
Lubricate the and insert the rubber grommets.
Lubricate the grommets and insert the header barbs.
Lubricate and slide the tube over the barbs.
TufGauge Pressure Gauge
To Install, screw the enclosed brass barb onto the
thread at the back of the Pressure Gauge using
Teflon sealing tape and two open end spanners (14
A/F & 16 A/F).
Drill an 8.5 mm hole in the PVC supply pipe and
clean the hole of any debris. Insert the tapered end of
the rubber grommet into the hole.
Lubricate the brass barb and insert it into the rubber
grommet, ensuring full engagement. Ensure the
pressure is between 1 and 100 kPa / 15 psi (top fed
systems 50 kPa / 7 psi max.).
STEP 7: Go to the end of the installed strips (known as
the Loop Return) and fold the strip in on itself. This will
allow the system to sit lower and neater to the roof. Apply
a small quantity of Prosil under the loop return to secure
it. Repeat the process for all looped returns.

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PLUMB THE SYSTEM TO THE PUMP HOUSE
Independent / Separate Suction System
The pool water is pumped directly from the pool to the solar collector and then back. This configuration requires
solar provisions to have been pre-installed. It is simple to install and does not interrupt the filtration system. This
type of plumbing allows the Solar System to operate independent of the filtration system.
Requires:
•1 x AS2, AS2_2S Digital Solar Controller or similar
•1 x Check Valve (also known as a Non-Return or One-Way Valve)
•1 x Solar Pump (that can deliver 3-4 litres per minute per m² of collector)
To Install
Identify and confirm the solar Supply and Return lines, even if they are labelled. This can be achieved by
removing the caps (if there are any) and yelling down the pipes or by pouring water down the line. The Suction
line should join at the swimming pool to two suction points, typically deep on the wall of the pool. The Return line
is typically a single return outlet, usually higher on the pool wall than the suction lines. Plumb as per the diagram
above. Ensure all pipework is dry and clean before attempting to glue.

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Simultaneous / Integrated / Retro Fit Configuration
This system involves diverting the flow of water after the filtration system. This system is usually adopted when
independent solar suction and return lines do not exist, as it is an easy way to retro fit a solar system without
affecting any other part of the pools structure.
Requires:
•1 x AS2_2S Digital Solar Controller or similar
•1 x Check Valve (also known as a Non-Return or One-Way Valve)
•2 x PVC Tees
•1 x Booster Pump (that can deliver 3 litres per minute per m² of collector)
To Install
Identify and confirm the Pool Return line that is running from the Pool Filter This can be determined by identifying
the return line on a filters multi-port valve when using a media filter or when using a cartridge filter identifying the
return port.
Switch the system off and isolate any valve/s (if possible) to minimise water loss. Identify the best position to cut
into the line to install the two PVC Tees, Check Valve and Pump. Plumb as per the diagram above. Ensure all
pipework is dry and clean before attempting to glue.

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Manual System (No Pump or Digital Controller)
Involves plumbing into the filtration line and manually opening and closing a three-way valve to divert water to the
system. This system does not require a Digital Controller or Solar Pump and is the cheapest way to plump the
system. However, you have very limited control over the heating process and must remember to go out and
adjust the valve if you want the system to operate. Before proceeding with this type of installation you should
determine the capacity of your existing pool pump. The plumbing must be cut in before any other pool equipment
(e.g. chlorinator cell, heat pump, gas heater etc.).
Requires:
•1 x Check Valve (also known as a Non-Return or One-Way Valve)
•1 x PVC Tee
•1 x 3-Way Manual Valve
To Install
Identify and confirm the Pool Return line that is running from the Pool Filter Switch the system off and isolate any
valve/s (if possible) to minimise water loss. Identify the best position to cut into the line to install the three-Way
Manual Valve, PVC Tee and Check Valve. Plumb as per the diagram above. Ensure all pipework is dry and clean
before attempting to glue.

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TROUBLESHOOTING RETURN SYSTEM PRESSURE
Bubbles upon start-up and shutdown are perfectly normal. If persistent bubbles are present in the pool
and you have Plumbing Configurations 1 or 2, please complete the following steps:
Step 1: Switch the system off and install a 2-way valve between the
return manifolds and the auxiliary heater and/or chlorinator cell
(if present).
Step 2: Switch the system back on, and move to the newly installed 2-
way valve
Step 3: Constrict flow in the return line using the lever handle by a small
increment.
Step 4: Wait a few minutes before checking the pool water. If air continues to bubble, constrict flow by another
small increment.
Step 5: Again, wait a few minutes before checking the pool water. If the air bubbles consistently stop, then the
system should be set at an acceptable positive pressure.
Step 6: Re-check that the pressure gauge is within the recommended pressure ranges.
Step 7: Leave the 2-way valve setting in place permanently by removing the handle.
If you have installed a system with Plumbing Configuration 3: Manual Driver Valve Connection the
following procedure for adjusting the Three-Way Valve for Manual Systems will need to be carried out:
Step 1: This process can be done with the vacuum valve’s top, and O-ring removed. However, be careful not to
misplace any components.
Step 2: Open the three-way ball valve by a small increment using the lever handle.
Step 3: Wait a few minutes and check if there is air still bubbling out of the return line.
Step 4: If air bubbles are still present, open the valve by another small increment.
Step 5: Continue opening the valve by small increments, until the air bubbles reliably stop.
Air Bubbles in Pool Water

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SERVICE AND MAINTENANCE SCHEDULE
Servicing and maintaining the system is essential for its health and longevity. The following table displays a
service and maintenance schedule that is recommended to be followed by the homeowner.
Maintenance Issue - Service Procedure
Monthly
Quarterly
Annually
TufFilta / Strainer: Depending upon your pool usage and level
of debris, the TufFilta / Strainer will need to be checked and
cleaned regularly
✓
Leaks: Check for leaks on a regular basis as leaks can corrode
metal roofs and gutters. Leaks should be repaired as soon as
possible.
✓
Non-Return Valve: The non-return valve (4 see plumbing
diagrams) is a critical system component. 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 (9) is a
critical system component. It should be checked that it is
functioning correctly and that collectors drain fully when the
pump stops. The collectors and/or piping should never appear
collapsed (concave) by negative pressure.
✓
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.
✓
Winterising System: You may need to prepare your system for
winter dormancy each year.
✓