Davey SolarMatic B3P-20 Manual

Premium Solar Pool
Heating System
Installation &
Operating Instructions
SolarMatic™
Please pass these instructions on to the operator of this equipment.

2
Table of Contents
Introduction ..................................................................................................................................................... 3
Specications .................................................................................................................................................. 5
General Layout of Completed System ............................................................................................................ 8
Basics Collector & Roof Plumbing ................................................................................................................... 9
Installation ..................................................................................................................................................... 10
Repairing a Damaged Collector Tube ........................................................................................................... 21
Appendix ....................................................................................................................................................... 22
Davey Repair or Replacement Guarantee ..................................................................................................... 24
Congratulations on your purchase of a
Davey SolarMatic®Premium Solar Pool
Heating System.

3
Davey Solar Solutions
Introduction
Davey Solar pool heating products are offered to the industry with the express expectation that the system will be
installed by an experienced, competent installer, in accordance with relevant Davey supplied documentation, the
Australian Standard AS 3634-1989 (Solar heating systems for swimming pools) and industry current best practices
and knowledge. Compliance with these expectations is a prerequisite of the Davey Solar Warranty.
As a service to the industry, Davey offers technical support and advice on how to best install Davey products, to
professional installers upon request, or by reference to the Davey Solar Installation Guideline and Training Manual.
This training manual contains a more detailed compilation of guidelines and recommendations on solar pool heating
system design considerations based on many years of experience and feedback from the industry.
Purpose & Scope
The intent of this manual is to equip the reader with the basic knowledge and skills to design, install, operate and
maintain the most common types of solar pool heating systems using collector and other components supplied
by Davey. This manual cannot cover all possible installation congurations, and does not include advice on non-
Davey components. The installer should contact Davey if there is any confusion or the details in this manual do not
adequately cover any particular installation. Failure to do so may void the Davey Solar Warranty.
Safety Precaution
Always exercise extreme caution, care and good judgement when working on or around a roof or pool area. There is
no substitute for safety. Do not use short cuts. The installer of any Davey solar pool heating system or component
must accept responsibility for assessing and implementing safety systems and procedures in accordance with all
moral and legal requirements and or any other regulatory authority. 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.
Solar Basics
The purpose of a pool solar heating system is to capture and collect solar energy, convert it to heat and raise the
temperature of the water in the swimming pool. Installing solar pool heating can increase the use of your pool by
up to four months. By using the energy from the Sun, heating a pool is very efcient and economical. The types of
solar pool heating systems can vary, but the basic principles remain the same. The efciency of the system depends
on how well the basic solar fundamentals are applied in its design and installation. (Refer Appendix A for further
information on Solar Pool Heating Fundamentals)
Collecting and Converting the Sun’s Solar Energy
The amount of heat absorbed and the resulting increase in pool water temperature depends on several factors which
need to be considered when designing and installing a solar pool heating system. The ultimate performance of the
system does not only depend on its design and material from which it is made, but also on the system’s size, type of
roof and available area, location and orientation, climate, shading of the system throughout the day, swimming pool
owner’s expectations, etc.

4
Location and Orientation
The collectors should be located such that the piping delivering the water to and from the collector and the pump is
as short as practicable. This ensures minimum heat losses and minimum pumping energy requirements.
Collectors (other than those on at roofs) should face in a northerly or north-westerly direction. This will ensure that
the collectors are heated by the Sun for the longest part of the day, or at least the hottest part of the day. Roofs that
face a north-easterly direction will require a larger collector area because it may be shaded from the hot afternoon
sun. South facing roofs are not suitable for positioning of solar collectors.
Collectors should be located so that they are not shaded by objects in front or to the North of the collector for at
least 6 hours per day during the pool heating season.
Size or Area of Roof
The amount of collector used for the solar pool heating system will have a major inuence on the effectiveness of
the system. The size of the system (collector area) is usually expressed in square metres, and as a general rule, is a
direct ratio compared to the surface area of the pool.
It is generally accepted that in northern Queensland a solar collector area of 70% of the surface area of the pool
would be considered adequate for a normal installation and swimming season. In southern states, such as Sydney
and Melbourne, systems with collector areas of 100% of the surface area of the pool would be recommended.
Larger systems may be required where higher than average water temperature, or extended swimming seasons are
desired.
For example: For a rectangular pool 4.5m x 9.0m, the surface area is 40.5 square metres. If 70% coverage is
required, then the total solar collector area will be 28 square metres (closest to 40.5m²). If 100% coverage is
required, then the total solar collector area will be 40 square metres (closest to 40.5m²). And so on.
Type of Roof Surface
The majority of roofs are constructed of either tiles or metal proles. The type of roof is important when selecting the
appropriate Davey Solar components or plumbing kit. Mechanical methods for xing the solar collectors, as well as
the manifolds/headers vary for the two different roof types.

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The Davey Premium Solar Pool Heating System
The Davey Premium Solar Pool Heating system is a trade quality strip collector system made up from ready to use
modular components that quickly and easily lock together. The systems are available in ve standard sizes, and are
made up from collector absorbers (cut to the appropriate length), a loop return assembly, two manifolds and four
Premium Barb Locks. The collectors come with Premium Moulded Manifold Barbs with Silicone O-rings pre-installed
from the factory and ready to assemble and lock together.
Models B3P-20 B3P-28 B3P-40 B3P-50 B3P-65
System Size: 21m² 27m² 40m² 50m² 65m²
Approx. Module
Length: 10 metres 10 metres 10 metres 13.2 metres 16.4 metres
No of Modules 7 9 13 13 13
Approx: Roof
Space Required*:
(2.2 x 10.2)
metres
(2.8 x 10.2)
metres
(4.0 x 10.2)
metres
(4.0 x 13.4)
metres
(4.0 x 16.6)
metres
* Dependant on roof type, Tiled or Tin (Refer to the chart on following page for Roof Height requirements.
Calculating the Correct Kit Size
Once the surface area of the pool is known, and the total area of the collector has been calculated, the kit size (in
square metres) and its conguration (number and size of each module) can be determined based on the roof area
available.
For example: For a rectangular pool 4.5m x 9.0m, the surface area is 40.5 square metres. If 100% coverage is
required, then the total solar collector area will be 40 square metres (closest to 40.5m²). A B3P-40m² kit would be
required. (refer following page)

6

Height of Roof (HR) required for No. Modules
Number of
Modules
HR metres
(Tin Roof)
HR metres
(Tiled Roof)
7 2.2 2.3
9 2.8 3.0
13 4.6 4.9
Length of Roof (LR) Space required for Different Module Sizes
Models 20m²
B3P-20
30m²
B3P-28
40m²
B3P-40
50m²
B3P-50
65m²
B3P-65
Roof Length LR 10.2 metres 10.2 metres 10.2 metres 13.4 metres 16.6 metres
Kit Size (m²) No. Modules No. Modules No. Modules No. Modules No. Modules
20 7
28 9
40 13
50 13
65 13
Length of Roof Space Required (LR)
Height of Roof Required (HR)
Number
of
Modules
N=1
N=2
N=3
N=4
N=5

7
Plumbing Kits
The systems come with a plumbing kit that contains all the necessary components and xtures required to
successfully install the collector panels. The exact contents of the plumbing kit will vary depending on the kit
ordered and number of modules needed, and whether the roof is made of tiles or metal cladding. The contents of a
typical plumbing kit are shown below.
The typical plumbing kit contains:
Not included with any kits.
• 40mmlengthsPVCpipe
• PVCglueandprimer
• Siliconelubricantspray
• Optionalisolatingballvalve
• 150mmwidepaintscrapper/spatula
• DaveySolarControllerorDaveypump
Item Davey Premium
Solar Kit Model B3P-20 B3P-28 B3P-40 B3P-50 B3P-65
1 Absorber Module L1000cm x W32cm 7 9 13 - -
1 Absorber Module L1300cm x W32cm - - - 13 -
1 Absorber Module L1600cm x W32cm - - - - 13
2 ProLok Barb Ends 280 360 520 520 520
3 ProLok Manifolds 4 18 26 26 26
4 Loop Return Assembly 7 9 13 13 13
5 ProLok Locking Clips 28 28 52 52 52
6 ProLok Roof Mounting Module 5 5 5 5 5
7 VacRel – Vacuum Relief Valve 1 1 1 1 1
8 TufFilta – Inline Solar Filta 1 1 1 1 1
9 TufGauge – Pressure Gauge 1 1 1 1 1
10 Joiner / Repair Barbs 10 10 10 10 10
11 Drain Down / Equalizer Kit 1 1 1 1 1
12 90 degree Elbow 4 4 4 4 4
13 45 degree Elbow 1 1 1 1 1
14 End Cap 1 1 1 1 1
15 40mm PVC Check Valve 1 1 1 1 1
16 40mm Pipe Saddle 5 5 5 5 5
17 TREMsil Silicone
Adhesive 7 9 13 13 20
2
1
8
17
15
13
14
5
10
12
6
16
7
9
11
4
5
3

8
General Layout of Completed Davey Solar Modular System

9
Basics Collector & Roof Plumbing Congurations
The preferred system conguration is a “Bottom Feed Solar System”, where the supply and return pipes are
plumbed from below the collector (refer below). This conguration provides:
• WiththesolarpumpswitchedON – swift air expulsion and hydraulic equilibrium and water ow throughout
the collector.
• WiththesolarpumpswitchedOFF – swift and efcient drain down back to the pool.
For certain installations, it may be necessary to plumb the system from above such as over a ridge capping.
Plumbing the supply and return pipes from above the collector is generally referred to as a “Top Feed Solar System”
(refer below). Top Feed systems have certain limitations and may result in long tern operational issues – and
therefore are not the preferred plumbing conguration.
This plumbing conguration provides:
• WiththepumpswitchedON - swift air expulsion and hydraulic equilibrium and water ow throughout the
collector.
• WiththepumpswitchedOFF - poor and inefcient drain down back to the pool and possible water stagnation
within the collector tubes.
NOTE: All top feed solar systems should be installed with the VacRel (VRV) at the highest point of the system, ideally
on the return line.

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Installation Techniques - Bottom Fed System (Preferred)
Step 1 – Cutting the Manifolds to Size (if required)
Tiled Roofs
• Asageneralrule,themouldedlengthofthemanifold,(400mmlong–allowingfor50mmgluejoin),willsuit
most tiled roofs and therefore little to no cutting back is required
Metal roofs
• Asageneralrulethemouldedlengthofthemanifoldwillrequirecuttingbackbyapproximately25mm(note
the two moulded lines) - conrm length prior to cutting! This will result in the collector modules butting up
neatly on the roof. Thoroughly de-burr edges and remove any loose material
Step 2 - Bonding Procedure - Manifold to Manifold.
Important! - Do not use any solvent primer on the Manifolds or any other ASA components. Wipe down joint areas
only with a clean cloth to remove any dust or other contaminants. Apply solvent primer only to PVC-U pipe ends
and/or ttings. Failure to comply may void warranty.
Do not apply any solvent cement to the female end of the manifolds. Apply Type N PVC cement to the MALE end
only - cover no more than 50mm. Ensure total coverage, but do not over apply the glue.
Insert male end into the female socket immediately after the cement is applied ensuring the full 50mm engagement
into the female socket, align the two arrow heads and hold together long enough to ensure retention.
After insertion a small bead of glue should be visible, wipe any excess clear with a clean cloth. Allow solvent cement
to dry for 24 hours before the system is turned on and pressurised with water.

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Step 3 - Fixing the Roof Mount onto the roof
The Roof Mounts are secured to the roof and retain the supply and return manifolds and the balance pipe (not
included in kit). It keeps the manifolds and pipe correctly aligned, reducing any induced stresses at the glued joints
due to thermal expansion - and it keeps the system neat and tidy.
NOTE: How the male T-track moulds into the back of the return manifold slides of the female T-track on the roof
mount.
The exact location of the Roof Mounts can be determined by temporarily inserting the pre-glued supply and return
manifolds into the mounts. The barb insert areas are off-set to align with the asymmetrical ends of the collector
modules. Locate a Roof Mount at either extremity of the manifold array. Space the remaining mounts equally
between these two. Pre drill holes into the roof mount that aligns with the xing points of either the tiles or the metal
cladding. Mark the location of the holes accurately.

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Tiled Roofs
• Usingamasonrydrill,drilltwoholeswheremarkedandinstalltheappropriateanchorplugs(notsuppliedin
kit) into each hole
• Placetherubbertilepackers(suppliedinatileroofplumbingkit)ontoeachendoftheProMountandxitto
the roof tile using appropriate self-tapping screws (not supplied in kit) through the rubber tile packer and into
the anchor plugs ensuring ample TREMsil silicone is used to seal the assembly
Corrugated Metal Roofs
• InstallationoftheRoofPackerontoacorrugatedmetalroofisthesameasatiledroof,exceptadifferent
rubber roof packer is required (supplied in a metal roof plumbing kit).
• PlacetherubbermetalroofpackersontoeachendoftheRoofMountandxittotheroofmetalroofusing
appropriate self-tapping screws (not supplied in kit) through the rubber packer and into the metal roof
ensuring ample TREMsil silicone is used to seal the assembly.
Flat metal Roofs
• Onatmetalroofsitisimportanttoelevatemanifoldsoutofthevalleystoensurewaterowisnotblocked.
• Fixappropriatespacerstrips(PVCormetalstrip50mmwidex3mmthick)bridgingtheridgesandthenxthe
ProMount to the top of the spacer strip.

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Step 4 - Installing the Manifolds and Balance Pipe
The balance pipe (not included in kit) should PN12 PVC-U pressure pipe that can be sourced through most plumbing
supply outlets. The balance pipe ensures equal pressure and ow rates throughout the collector system, and is
required to ensure the correct operation and performance of the system.
• Slidethepre-gluedRETURN (front) Manifold assembly into the T-slot of the xed Roof Mounts
• Clipthepre-gluedSUPPLY (middle) Manifold assembly into the centre clip of the Roof Mount
• CliptheBalancepipeintotherearclipoftheRoofMount

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Step 5 - Plumb the Top of The Manifold System
NOTE: It is advisable to plumb the top of the manifold system only after the rst length of collector has been laid;
this procedure ensures correct Manifold alignment with the asymmetrical Collector.
Plumb the Top of the Manifold System as shown below.
• TheRETURN (front) Manifold is installed higher up the roof compared to the rear mid positioned manifold. It
needs to be connected to the rear balance pipe using 2 x 40mm 90 degree elbows and a short length (approx.
105mm) of 40mm PN12 pressure pipe
• TheSUPPLY (middle) Manifold is capped off using the VacRel vacuum relief valve and a 45 degree elbow
(supplied) or 90 degree elbow (optional) – depending on the pitch of the roof. The VacRel valve should be as
close to vertical as possible
NOTE: How the 40mm elbow is bonded to the manifold slightly angled downward in order for it to align with
the lower balance pipe. To assist the installer aligning the two components of the manifold with the longitudinal
alignment line. refer below

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Step 6 - Installing the Collector Modules
Start at the upper most Manifold.
• rolloutone(1)Collectormodule
• LubricatetheManifoldandtheredSiliconeo-ringbarbs
• PartiallyinserttheredSiliconeo-ringbarbsintotheManifold
• Usinga150mmwidepaintscrapperorspatula,(Notsuppliedinkit)ensureall10redSiliconeo-ringbarbsare
fully inserted into the Manifold
• CliptheManifoldClipintotheManifoldensuringthattheformedslotsarefacingoutward(notetheseslots
assist with clip removal if required).

16
NOTE: Minimise overspray and cross contamination of the silicone spray onto other surfaces. (Excessive overspray
will contaminate the work site that may lead to poor THEMsil adhesion and a possible slippery / unsafe roof working
surface for personal). Tip - the use of a cloth under or around the spray site is a good technique to control over-
spray, wipe your hands regularly with a clean cloth.
Step 7 - Installing the Loop Modules
Starting at the upper most collector module:
• LubricatetheLoopmanifoldandtheredsiliconeoringbarbs
• Partiallyinserttheredsiliconeo-ringbarbsintotheLoopmanifold
• Usinga150mmwidepaintscrapperorspatula,(Notsuppliedinkit),ensureall10redsiliconeoringbarbsare
fully inserted into the Loop manifold
• CliptheManifoldClipintotheLoopReturnManifoldensuringthattheformedslotsarefacingoutward(note
these slots assist with clip removal if required)

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Step 8 - Fixing the Collector to the roof
• Startingfromthetopofthesystemandworkingdowntheroof,applyatthetopandbottomoftheCollectora
generous 50mm long bead of TREMsil Silicone (translucent or black) directly to the roofs surface
• AgenerousbeadofTREMsilsiliconewillbesufcientformostaverageinstallationstoadheretheCollector
strips for the life of the system provided the two surfaces are clean and dry
• ThebeadsofTREMsilshouldbenomorethan600mmlaterallyapartformostaverageinstallations
• Pushthestripsdownrmly;ensuringamplesurfacecontactbetweenthetwosurfaceshasbeenachieved
• Repeattheprocessworkingdowntheroofuntilallcollectorshavebeeninstalled
• Ensurethecollectorisinstalledinarelaxedstatesuchthatthecollectorisnotapplyingtensionontothe
manifold system
• Thereasonforinstallingandadheringthecollectorfromthetopofthesystemandworkingdowntheroof
is to allow the installer the ability to easily reach over the previously laid collector and apply the TREMsil
adhesive from below without the need to stand or kneel on the collector or excessively lean over the laid
collector

18
Step 9 – Plumbing the Bottom of the Manifold System
Plumb the bottom of the Manifold System as shown below.
• CaptheRETURN (front) Manifold with a 40mm cap at the base
• ConnecttheSUPPLY (middle) Manifold to the 40mm PVC-U pressure pipe (PN9 or PN12 - not supplied in kit)
delivering pool water to the collector system from the solar pump
• Connectthebalanceofthemanifoldsystemtothe40mmPVC-Upressurepipe(PN9orPN12–notsupplied
in kit) return line, feeding the heated water back to the pool
• Notethepositionofthepressuregauge
NOTE: It is important that the Manifold system and the supply and return pressure pipes are securely installed
onto the roofs surface in order to resist induced external forces such as wind etc. This can be achieved by using
an appropriate number of 40mm saddle clamps. However, the entire system must also be installed to allow for all
thermal movements (Both the Manifolds and connecting pipes) without induced longitudinal or lateral stress being
applied to the manifold system.

19
Step 10 - Installing the Pressure TufGauge
The TufGauge must be installed in the supply pipe only, just below or close to the rst collector strip. This is the
point in the solar system where the pressure at the collector tubing is the highest.
To install the TufGauge:
• AssemblethesuppliedbrassbarbontotheTufGaugeusingTeonsealingtapeandtwoopenendspanners
(14 A/F & 16 A/F) to ensure a permanent pressure tight assembly without applying any stress to the stainless
steel casing of the gauge.
• Drilla9.0mm(or11/32”)holeinthePVCsupplypipeintheappropriatepositionandorientation,ensurethe
drilled wad, swarf and burrs are removed.
• Insertthesuppliedrubbergrommet,taperedendintotheholeensuringtheheadsitsushwiththeoutsideof
the pipe – do not use any form of lubricant.
• Lubricatethebrassbarbwithsiliconelubricant,andinsertthebrassbarbintotherubbergrommetensuring
full engagement.
The TufGuage is designed to be a permanent xture of the pool solar heating system. It allows the installer
to accurately and quickly perform the required AS 3634-1989 9.2(g) pressure test in accordance with the
allowable limits below and the Boss Polymer product warranty.
Bottom Feed Systems designed and installed to automatically fully drain
• 100kPamax.(15psi)(measuredatrecommendedlocationwithaTufGauge)
Top Feed Systems
• 60kPamax.(9psi)(measuredatrecommendedlocationwithaTufGauge)

20
Step 11 - Installing the In-Line Solar TufFilta™
Install the TufFilta™ in-line cartridge lter directly after the solar pump.
The TufFilta should be positioned to allow for easy access for maintenance, and be clear of other equipment that
may be sensitive to pool water that may spill during cartridge element replacement.
An isolating valve (not supplied in kit) can be installed immediately downstream of the lter to enable removal of the
strainer for cleaning without purging any water left in the line between the lter and the drain down tube.
Step 12 – Installing the Drain-Down Tube
A drain down tube needs to be installed connecting the supply and return pipes to assist with system drain down
when the solar pump is turned off - ensuring no stagnant water in the collector system. The connection should be
done between two vertical sections of the pipes, located above the maximum water line of the pool.
• Drilla9.0mm(or11/32”)holeineachPVCpipeintheappropriatepositionandorientation,ensurethedrilled
wad, swarf and burrs are removed
• Insertthesuppliedrubbergrommets,taperedendintotheholeensuringtheheadssitushwiththeoutsideof
the pipes – do not use any form of lubricant
• Lubricatetheshortendsofthesuppliedbarbswithsiliconelubricant,andinsertthebarbsintotherubber
grommets ensuring full engagement
• CutthesuppliedEPDMtubingtoaconvenientlength(withoutstretchingorkinkingwhen