Boss Solar Rhino PAR3 Installation guide

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DISCLAIMER
Please read and familiarise yourself with the instructions outlined in this manual before attempting
installation. If you have product or installation questions, please contact your local authorised Rhino Solar
representative or in their absence, Boss Solar head office for assistance.
Installing a Solar Pool Heating system is potentially dangerous, primarily due to working at height issues plus
other potential hazards such as electrical wires and loose tiles/shingles etc. By purchasing this product, the
purchaser accepts all responsibility to take their own safety precautions while installing or using this product.
Boss Polymer Technologies does not take any responsibility for any injuries or death whilst installing this
product. For information on safe working in your region visit your state worksafe website.
Relationship to Boss Product Warranty
Whilst Boss Solar’s warranty is limited to covering the Rhino systems using Boss components, Boss
acknowledges that there are a number of highly regarded professional Installers whose installations may not
strictly adhere to the recommendations and guidelines set out in this manual. This may be through the use of
non-Boss components or alternative installation methods, adopted as a result of historical and/or geographical
preference for their own ‘time proven’ methods.
On the proviso that Boss is satisfied that any system/components failure is not a direct result of any deviation
from this manual, it is at Boss Solar’s discretion as to whether the warranty will be honoured.
If you require a copy of the Rhino Warranty, visit on our website: https://www.bosssolar.com.au/downloads

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TABLE OF CONTENTS
Technical Specifications .............................................................................................................................................................3
Panel Options and Sizes .............................................................................................................................................................4
Panel Set & Parts........................................................................................................................................................................6
Before You Start.........................................................................................................................................................................7
Required Tools ......................................................................................................................................................................7
Definitions.............................................................................................................................................................................8
Panel Sets and Balanced Flow ...............................................................................................................................................9
How Many Panels Should I Join Together?..........................................................................................................................13
Balanced Flow .....................................................................................................................................................................13
How To Install Rhino Solar........................................................................................................................................................14
Appendix 1: Choosing the Correct Panels and Roof for Your Install ....................................................................................16
Appendix 2: Plumbing Considerations, Getting Around Obstacles and Automatic Drain Down ..........................................18
Appendix 3: Marking the location of the Roof Mounts........................................................................................................20
Appendix 4: Installing the Roof Mounts on Metal Roofs .....................................................................................................21
Appendix 5: Installing the Roof Mounts on Tiled Roofs .......................................................................................................22
Appendix 6: How to Connect the Solar Panels Together (Installing the Ring Clamp Assembly) ..........................................23
Appendix 7: Connecting the Panel System to the Supply and Return Lines........................................................................24
Appendix 8: Installing the End Caps.....................................................................................................................................25
Appendix 9: Connecting the Supply and Return Lines from the Roof to Ground Level.......................................................26
Appendix 10: Plumbing Configurations ...............................................................................................................................28
Appendix 11: How to Install a Vacrel®.................................................................................................................................32
Appendix 12: How to Install a Pressure Gauge....................................................................................................................33
Appendix 13: How to Install the Drain Tube........................................................................................................................34
Appendix 14: How to Install the TufFilta®............................................................................................................................35
Appendix 15: Operating and Check out Procedures............................................................................................................36
Appendix 16: Pressure Testing the System..........................................................................................................................36
Appendix 17: Troubleshooting ............................................................................................................................................37
Appendix 18: Maintenance Schedule ..................................................................................................................................40
SRCC Certification / Thermal Performance Rating...............................................................................................................41
Panel Pressure Drop............................................................................................................................................................42

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Technical Specifications
Product Name
Rhino Solar Pool Heating Panel
Manufacturer
Boss Polymer Technologies PTY LTD
Place of Manufacture
Victoria Australia
Solar Panel Type
Unglazed Flat Plate
Solar Panel Configuration
Polypropylene Strip Panel
Certification:
•Certified ICC 901\SRCC 100-2015,
•Performance Rated ISO 9806
•Certified Hail Resistance ISO 9806
•Climate Care SPASA Australia
Materials:
•Header & Collector
•Roof Clamp System
•Panel to Panel Couplings
•PVC Pipe Coupling
- Co-Polypropylene - High Heat, High Impact, UV Stabilised
- Glass Reinforced Polypropylene - High Heat, High Impact,
UV Stabilised
- Polypropylene - High Heat, High Impact, UV Stabilised
- CPVC –Chlorinated Polyvinyl Chloride, High Heat, High
Impact, Solvent Crack Resistant, UV Stabilised
Number of Tubes
PAR3
PAR6
30
60
Tube Outside Diameter
10.5 mm
Tube Inside Diameter
8mm
Tuber Wall Section
1.25mm
Tube Pitch
15.7mm
Header Pipe Outside Diameter
51mm
Header Pipe Wall Thickness
5.5mm
Average Flood Weight (panel + water)
6.42kg/m2
Maximum Recommended Operating
Pressure at 60°C
500 kpa
Daily Energy Output / Thermal
Performance Rating
Refer page 41
Panel Pressure Drop
Refer page 42

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PANEL OPTIONS AND SIZES
PAR3
Rhino Part Number.
PAR3/010
PAR3/014
PAR3/018
PAR3/023
Panel Length, mm
1675
2430
3195
3970
Panel Width, mm
575
575
575
575
Panel Gross Collector area, m²
0.96
1.39
1.83
2.28
Panel Active Collector Area, m²
0.7
1.1
1.5
1.9
Panel Aperture Collector Area, m²
0.8
1.2
1.6
1.9
Total Thermal Collection Area, m²
0.78
1.14
1.49
1.85
Panel Weight (Dry Weight) kgs
3.243
4.111
5.162
6.135
Total Water Volume Capacity, litres
3.14
4.72
5.68
6.78
Panel Weight (Wet) kgs
6.383
8.831
10.842
12.915
Panel Weight (Wet/m²) kgs/ m²
6.7
6.35
5.93
5.69
Rec. Flow Rate, litres/min/Panel
3.8
5.5
7.3
9.1

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PAR6
Rhino Part Number
PAR6/018
PAR6/026
PAR6/034
PAR6/042
Panel Length, mm
1675
2430
3195
3970
Panel Width, mm
1.070
1.070
1.070
1.070
Panel Gross Collector area, m²
1.78
2.59
3.41
4.23
Panel Active Collector Area, m²
1.5
2.3
3.0
3.8
Panel Aperture Collector Area, m²
1.6
2.4
3.1
3.9
Total Thermal Collection Area, m²
1.56
2.26
2.97
3.69
Panel Weight (Dry Weight) kgs
6.33
8.06
10.15
12.09
Total Water Volume Capacity, litres
6.39
9.6
11.9
14.2
Panel Weight (Wet) kgs
12.72
17.66
22.05
26.28
Panel Weight (Wet/m²) kgs/ m²
7.18
6.83
6.48
6.22
Rec. Flow Rate, litres/min/Panel
7.1
10.4
13.6
16.9

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PANEL SET & PARTS

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This installation guide was designed to explain how to properly install a Rhino Solar system under normal
circumstances. However, it cannot possibly address all situations or requirements. If you have any questions
or issues, please contact your local authorised Rhino Solar representative or in the absence, Boss Solar head
office for assistance.
•Ensure you have taken all necessary safety precautions before beginning
•As the installer, you are responsible for exercising good judgment when installing Rhino Solar to
protect the long-term integrity of the collectors as well as the mounting surface(s)
•Check the code and permit requirements from your local building department before commencing
any works
•Familiarise yourself with all Rhino Solar components and plumbing materials required to complete
the installation
•To ensure that you avoid breaking/cracking any roof tiles, try to walk on the ‘crease’ of the tile, not
the middle. If you break a tile you should replace it. On tin roofs, walk on the screw/nail line. Walking
elsewhere may cause the metal roof to crease.
•For safety reasons, avoid standing or walking on the Rhino Solar panels whenever possible, whilst
the panel will take your weight, panels generally have less grip when compared to normal roof
surfaces, particularly when wet. Ideally, panels should be installed with ample clearance around the
assembled panels to allow accessed without being walked on.
•A Schematic Drawing should be prepared before starting any work. Ensure you have accurately
measured the available roof space and marked any roof protrusions or obstacle. This will allow you to
determine the appropriate location and orientations of your system.
•Depending upon your installation, additional plumbing materials and items may be required. When
selecting additional material please ensure you select:
oQuality products that are capable of withstanding long-term direct UV exposure
o40mm pressure rated to class 9 or higher, PVC pipes and fittings
oUse good quality “multi-purpose” PVC Cleaners and Cement
•Do not use ABS, “plumber’s” fittings, DWV fittings (drain, waste, and vent) or a lower standard
substitute.
•It is important to remember that no two installations are exactly alike. However, most standard
installations do share similarities.
Required Tools
Before beginning the installation, it is a good idea to check that you have all of the necessary tools and
materials on hand. Below is a list of the typical tools and materials that are useful to have:
•Appropriate safety
equipment such as guard
rails, harness gear, safety
belts, hard hats, stable roof
access ladder etc.
•Battery Drill (with Hammer
Function if drilling into tiles or
masonry if required)
•Masonry Drill Bits to suit
Green Screw Plugs
•Flat Head and Phillips Head
Screwdriver
•Chalk/String Line
•Chalk or Marking Pen
•Suitable Fixing Screws
•Pliers
•Teflon Sealing Tape
•Spirit Level
•Pipe Cutter or Hacksaw
•Tape Measure
•Caulking Gun
•PVC Cement
•PVC Primer
BEFORE YOU START

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Definitions
What Is a Bank of Panels?
A single Bank of panels is where a set of multiple panels of the same length are interconnected at both the Top
and Bottom Headers by a Ring Clamp assembly only.
When panels Banks are separated by PVC pressure pipe, the system has more than one Bank.
What is an Array?
A single Array is an interconnected lot of Panels (may be various length panels and may be mounted on
different roofs) with ONLY One Supply Inlet and ONLY One Return Outlet.
What Is an Extension?
If Banks of panels are interconnected at more than TWO connection points, then any additional
interconnection is referred to as an Extension.
What is a System?
A system refers to the total solar pool heating system to heat one volume of water.

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Panel Sets and Balanced Flow
Single Row
One Array
Double Row / Parallel Feed
Two Panel Banks, Two Arrays

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Single Row / Split Feed
Two Panel Banks, Two Arrays
Series Feed
Two Panel Banks, Two Arrays
Double Row / Parallel Feed
Four Panel Banks, Four Arrays

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Series Feed / Different Roof Slopes
Two Panel Banks, Two Arrays

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Series Feed / Opposing Roof Falls
Two Panel Banks, Two Arrays
Series Feed / Triangular Roof
Three Panel Banks, Three Arrays

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How Many Panels Should I Join Together?
The most common and preferred configuration is in a continuous row. However, there are recommended
limits to the number of panels that can be installed in this way due to potentially excessive thermal
expansion/contraction issues and correct water flow throughout and across the panel array.
Balanced Flow
Wherever possible the return PVC line should have the shortest possible run back to the pool to reduce heat
loss as much as possible (Figure 1).
If the system exceeds the maximum number of panels per continuous row (see table above) `or is across
separate roofs, splitting the system is very beneficial (Figure 2).
Never plumb the supply inlet and return outlet to the same end of a panel array as this will reduce heating
performance as it doesn’t allow for a balanced and even water flow across the array. (Figure 3).
Panel Model
Part Number
PAR3/010
PAR3/014
PAR3/018
PAR3/023
PAR6/018
PAR6/026
PAR6/034
PAR6/042
Maximum
Panels/Bank
16
16
16
16
9
9
9
9
Potential
Header
Movement
(Width)
88mm
88mm
88mm
88mm
93mm
93mm
93mm
93mm
Potential
Collector
Movement
(Height)
15mm
21mm
28mm
35mm
15mm
21mm
28mm
35mm
Figure 1: Reverse End Return
Figure 2: Double Row
Figure 3: Same End Return

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HOW TO INSTALL RHINO SOLAR
Step 1:
Determine the roof/s where the panels will be installed, taking into consideration the space,
orientation, roof protrusions, roof slope and shading. Appendix 1 ‘Choosing the Correct Panels
and Roof for Your Install’
Step 2:
Take into consideration the position of the plumbing, what obstacles are on your chosen roof
and making sure the system can automatically drain down. For more information refer Appendix
2 ‘Plumbing Considerations, Getting Around Obstacles and Automatic Drain Down’
Step 3:
Choose an appropriate position for the top roof mounts. Measure out a datum point and mark
with a chalk line. To allow for proper drainage for winterisation, please ensure the line has a
slight slope of approximately 25mm per 3 metres down towards the supply side of the array.
If you are installing on a metal roof, mark the line ideally over a batten
If you are installing on a tiled roof, ensure that the line is 50mm above the bottom of the tile, to
allow any built-up debris above the header pipe to be washed away by the natural flow of the
water. If the pipe is installed too close to the bottom edge of the upper tile, the natural water
flow would not be able to wash any built up debris away, therefore potentially causing roof leaks
as the water builds up behind the debris and flows under the roof tiles
Please note: If a slope is not possible, perhaps due to a unique roof design, then automatic drain
down will not occur. In this instance, please ensure you install manual drain valves as needed and
formally instruct the homeowner of the need to winterise the system.
Step 4:
Using the diagram and table below, create a horizontal sloping line where the bottom Roof
Mounts will be installed.

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Step 5:
Move to the top chalk line and mark the location of the Roof Mounts, see Appendix 3 ‘Marking
the location of the Roof Mounts’
Step 6:
Install the lower half of the Roof Mounts, ensuring you are following the steps outlined for your
particular roof type surface. If you are installing on a metal roof, refer to Appendix 4 ‘Installing
the Roof Mounts on Metal Roofs’. If you are installing on a tiled roof, refer to Appendix 5
‘Installing Roof Mounts on Tiled Roofs’
Step 7:
Hang the panels into the Lower Half of the installed Roof Mounts.
Step 8:
To stop the panel/s from sliding off the roof, place the Upper Half of the Roof Mount over the
Lower Half and push them down lightly, do not fasten the screws as you may need to remove
the roof mount to complete panel to panel connections
Step 9:
Join the panels together along the top of the system using the procedure outlined in Appendix 6:
‘How to Connect the Solar Panels Together (Installing the Ring Clamp Assembly)’
Step 10:
Moving to the bottom of the system, follow the instructions outlined in step 9 to connect all
panels together using Ring Clamp Assemblies
Step 11:
Install the two (2) supplied screws into the Roof Mount to secure its Upper Half to its Lower Half.
Continue until all Roof Mounts have been secured
Step 12:
Connect the Supply and Return lines to the panel array in accordance with the steps outlined in
Appendix 7 ‘Connecting the Panel System to the Supply and Return Lines’
Step 13:
Install the end caps on the opposite corners to the supply and return lines, see Appendix 8
‘Installing the End Caps’ for details
Step 15:
Run the Supply and Return lines down the side of the building to the equipment pad, ensuring
you use the appropriate 45° or 90° elbows and saddle clamps, see Appendix 9 ‘Connecting the
Supply and Return Lines from the Roof to Ground Level’
Step 16:
Connect the Supply and Return lines as per your chosen plumbing configuration, see Appendix
10 ‘Plumbing Configurations’
Step 17:
Install a Vacrel®, see Appendix 11 “How to install a Vacrel®
Step 18:
*Optional* Install a TufGuage®, see Appendix 12 ‘How to Install a Pressure Gauge’
Step 19:
Install a Drain Tube, see Appendix 13 ’How to Install the Drain Tube’
Step 20:
*Optional* Install a TufFilta®, see Appendix 14 ‘How to Install the TufFilta® Inline Solar Filter’for
details
Step 21:
Allow 24 hours for all adhesives to set prior to pressurising the system. To pressurise the system,
follow the steps outlined in Appendix 15 ‘Operating and Check-out Procedures’
Step 22:
Now that the system is fully installed and pressure checked, complete your final operating and
check-out procedures found in Appendix 16 ‘Pressure Testing the System’
Step 23:
If you encounter any issues, consult Appendix 17 ‘Troubleshooting’
Step 24:
Formally instruct the homeowner through a required maintenance schedule to keep their new
system working at peak performance, see Appendix 18 ‘Maintenance Schedule’

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Determine the roof(s) where the panels will be installed, taking into consideration the space, orientation, roof
protrusions and shading. The selected roof(s) should be exposed to the sun for most of the day, with minimal
shading or obstructions. The best orientation depending on your hemisphere as outlined in the following table:
Roof shading from trees, other buildings or obstacles must be considered when selecting a suitable roof
installation site. However, a degree of shading can be compensated by installing a greater quantity of panels.
Determine how the Rhino Solar panels will fit on the roof(s) and select an appropriate panel configuration. The
most common and preferred configuration is in a continuous row. Remember to plan for any roof obstructions
when selecting a Rhino panel configuration.
Select the appropriately sized Rhino Solar panel(s) to suit your desired configuration and mounting location.
Use larger panels where possible to minimise panel connections, lower installation time and reduce costs.
Before undertaking any work, it is important to prepare a detailed Schematic Drawing/Diagram outlining the
position and dimensions of the panel(s), Supply and Return pipe work in relation to the roof surface and pool
location.
Appendix 1: Choosing the Correct Panels and Roof for Your Install
Orientation
Priority
Southern
Hemisphere
Northern
Hemisphere
Best Option
North Facing
South Facing
Second Best
Flat Roof
Flat Roof
Third Best
West
West
Forth Best
East
East
Not Recommended
South Facing
North Facing

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Calculating How Many Panels Are Required
To identify how many panels will be needed, you must first calculate the surface area of the pool in m² and
then calculate the panel size and quantity required based on the combined systems Panel Nett (Active)
Collector Area (m²) as a percentage (%) to the Pools surface area (m²).
The following section will give you the information needed to calculate the total square metres of panels
required.
Calculating the Surface Area of a Rectangular or Square Pool
To calculate the surface area of a rectangular or square pool multiply the width of the pool by its length (width
x length = surface area). For example, if the pool is 9 metres by 5 metres then the surface area of the pool is 45
square metres (m²).
Calculating the Surface Area of an Oddly Shaped Pool
To calculate the surface area of an oddly shaped pool:
Visit Google Map Developers at https://www.mapdevelopers.com/area_finder.php
Ensure you select the “Satellite” option to view and measure your pool surface area.
Calculating the Size and Quantity of Rhino Panels Required
The size and quantity of Rhino Panels required must be large enough and correctly positioned on the roof to
heat the pool efficiently. For the average customer and installation, it is generally accepted that in cooler
climates such as Melbourne or San Francisco, the total surface of the Rhino Panels should be equal to between
80% - 100% of the pools surface area. In warmer climates such as Queensland or Florida, panels should cover
between 60% - 80% of the surface area of the pool, according to Australian Standards AS 3634-1989.
This amount may vary depending on several factors, including: Customers Expectation, Pool Blanket, Climate,
and the Available Roof Space.
To calculate the required total panel surface area, simple multiply the pools surface area (m²) by the desired
percentage (%) and divide by 100. For example, to provide 80% surface area of Rhino panels for a 45 square
metre pool, 36m² of Rhino Panels would be required.

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Getting Around Obstacles
There are several options when you need to install around an obstacle such as Skylights and Flues, the method
depends on the dimensional size of the obstruction and its location.
If the obstacle is greater than 80mm the traditional method is to arrange the panels either side of the obstacle
and then bridge the obstacle gap between the two (2) joined panels on either side of the obstacle using PVC
Pipe Spacers. An alternative method is to either fully remove and plug any interfering collector strips from the
headers or to cut the collector strip around the obstacle and then plug the Headers wherever the collector
tubes have been cut and removed. The decision to use either method is up to the installer and the size and
location of the obstacle, however Rhino Manifold Plugs can be a more convenient, faster, and aesthetically
appealing option for smaller obstructions.
PVC Pipe Extensions
When you need to install panels either side of an obstruction greater than the normal 80mm gap between two
joined panels, the traditional PVC pressure pipe, Pipe Spacer method to circumnavigate the obstacle is
generally used:
Step 1:
Measure the length of the obstruction and cut two pieces of 40mm PVC pressure pipe long
enough to circumvent the obstacle. You may need to take an additional 40mm into consideration
to account for the 2 x CPVC Pipe Couplings or a further 100mm to account for any rubber flexible
coupling/s where required.
Step 2:
Once you have deburred the PVC pipe(s), prime and cement two (2) CPVC Pipe Couplings to
either end. Ensure that you use a good quality, multi-purpose cement.
Step 3:
Connect the PVC Pipe Spacer assembly to each Header Pipe to bridge the gap, using two (2) Ring
Clamp Assemblies per PVC Pipe Spacer, see Appendix 6 for instruction on installing the Ring
Clamp Assembly.
Step 4:
To prevent the PVC pipe from sagging, you may consider installing 50mm (2 inch) pipe clamps or
additional Roof Mounts along the top PVC pipe at regular intervals. For the bottom PVC pipe, you
will need to allow for thermal expansion/contraction of the Solar Panels can be installed. This
may not be necessary if the distance is less than 600mm (24 inches).
Appendix 2: Plumbing Considerations, Getting Around Obstacles
and Automatic Drain Down

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Manifold/Header Plugs
Automatic Drain Down
All Solar Systems should be installed in a manner that will allow the water to drain automatically and
completely, each and every time the pump is switched “OFF”. This is extremely important as water left in the
system can cause a variety of issues that may affect the integrity of your system. This is especially important in
areas subject to freezing conditions.
If the system cannot be designed to automatically drain down (possibly due to a unique roof design) then
manual drain down valves should be installed in the plumbing or at the end of the bottom (supply) header. If
this procedure is employed, it is important to train the pool owner in the proper drain-down procedure for
winterising the system.
Systems installed on flat roofs may require additional help when draining down by opening the collector
connections and manually lifting the panel to empty the residual fluid.
Alternatively, you may wish to install a Solar Controller that has an ANTI-FREEZE/BOIL function (such as the
Dontek AS5 or Dontek AS5RTS).
These type of controllers sense when the temperature on the roof reaches the anti-freeze setting (the
temperature at which the system can experience damage from the stagnant water freezing) and will switch
the pump on for 5 minutes then turn off for 15 minutes. It will continue this sequence until the roof
temperature rises above the anti-freeze temperature. It has a similar function to protect the flooded system
from boil damage (damage from the stagnant water over heating).