EcoOnline PoolMasterpro User manual

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 1
EcoOnline PoolMasterpro™
14 Tube PVCn Strip Collector
Solar Pool Heating System
Installation and User Manual - Revised 20/11/2020
Optex Solar Pty. Ltd.
ABN: 88 128 228 884
www.EcoOnline.com.au
email: [e-mail]
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved. This publication is protected by copyright law
and unless otherwise specified is for your personal and non-commercial use only. No part of this publication
may be reproduced or distributed by any process, electronic or otherwise, without the specific written
permission of Optex Solar Pty Ltd. Trademarks appearing in this manual are the sole property of Optex Solar
Pty Ltd or their respective owners. Nothing in this publication shall be construed as granting any express or
implied license to use any intellectual property of Optex Solar Pty Ltd otherwise than for personal and
non-commercial use only. Optex Solar Pty Ltd must not, to the full extent permitted by law, be held liable
for any claim, cost (including legal costs), damage, expense, loss (including fines, penalties, set-offs and
consequential loss) or liability arising from the use (or misuse) of any product described in this
publication, unless expressly provided otherwise in this publication. Information as well as any
products described in this publication are subject to change without notice.

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 2
Contents
1Key Terms
2Pre-Installation Suitability and Safety Checklist
3Warranties
4Collector Sizing Guide
4.1 A Word on Transparent Bubble Pool Covers
5Pool Chemistry Compatibility Guide
6Pump Sizing Guide
6.1 A Word on Pump Sizing Choice
6.2 Quick Reference Solar Pump Sizing for Independent Systems
6.3 Solar Pump Sizing for Booster Systems
6.4 Filter Pump Sizing for Manual Systems
7Solar Line PVC Pipe Sizing Guide
8Collector Array Components
9Required Components (Not Supplied)
10 Required Tools
11 Safety When Working at Heights
11.1 Ladder Safety
12 Choosing a Place to Install the Collector Array
13 Collector Water Flow Configurations
13.1 Bottom Feed Basic (Square, Parallelogram or Trapezoid)
13.2 Top Feed Basic (Square, Parallelogram or Trapezoid)
13.3 Narrow Roof Space Multi-Loop Configuration
13.4 Narrow Roof Space Extra Manifolds Configuration
13.5 Other Custom Narrow Roof Space Extra Manifolds Configurations
13.6 Double Manifold High Flow Narrow Roof Space Configuration
13.7 Bottom Feed Overlap (Square, Parallelogram or Trapezoid)
13.8 Top Feed Overlap (Square, Parallelogram or Trapezoid Layout)
13.9 Bottom Feed Butterfly (for long 25m collector arrays)
13.10 Top Feed Butterfly (for long 25m collector arrays)
13.11 Multi-Directional Opposing Bottom and Top Feed Arrays
13.12 Multi-Directional Curve Around Arrays
13.13 Sharply Tapering Trapezoid Arrays
13.14 Bottom Feed In-Parallel Split Arrays (For Multi-Level Split Arrays)
13.15 Bottom Feed In-Series Split Arrays (Low Pitch Roof Only)
13.16 Plumbing Configurations Not Recommend

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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14 Adjusting Strip Spacing by Cutting Manifold
15 Adjusting Strip Spacing for Angled Manifold Runs
16 Roof Assembly and Attachment
16.1 Tile Roof Mounting of Manifold Assembly
16.2 Corrugated Metal Roof Mounting of Manifold Assembly
16.3 Manifold Gluing Procedure
16.4 Connecting the Tubes to the Manifold Barbs
16.5 Strip Collector Assembly and Gluing
16.6 Alternate Strip Tile Layout for Short or Long Ledge Tiles
17 Extra Wind Proofing
17.1 Roof Edge Exclusions Zones
18 Collector Installation Order and Procedure
19 Plumbing Diagram Configurations
19.1 Configuration 1: Independent/Separate System
19.2 Configuration 2: Integrated Independent System
19.3 Notes on Teeing into the Suction Line for Configuration 2
19.4 Configuration 3: Manual/Timer/ Motorized Valve System
19.5 Configuration 4: Booster/Retrofit System
20 Installing the Controller for Independent Systems
20.1 Installing the Roof/Hot Sensor
20.2 Installing the Pool/Cold Sensor
20.3 Extending Sensor Cords
21 Drain-Down, Frost Proofing and Winterization
21.1 Drain Down
21.2 Winterization
21.3 Installing a By-Pass Tube or By-Pass Ball Valve
22 Optimizing Collector Pressure
22.1 Installing the Pressure Gauge
22.2 Pressure Check Procedure
22.3 Negative Pressure and Air Bubble Issues
22.4 Adjusting the 3 Way Valve for Manual Systems
22.5 Optimizing Pressure for Oversized Pumps
23 Checking for Balanced Water Flow
24 Service and Maintenance Schedule
24.1 Collector Puncture Repair Procedure
25 Important Installation Check List

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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1Key Terms
This manual was written to follow guidelines and recommendations given in:
AS 3634 - 1989 Solar heating systems for swimming pools
‘HAZPAK’ produced by the work-cover authority
AS 3000 (2007) Sections 6.3, 6.4 & 6.5
Please take the time to read this manual before starting any work. Particular attention should be given to text
contained in the following key terms.
Please note EcoOnline has a strong product safety policy; do not install products without reading safety guidelines in
the manual. Please report any product safety issues or near misses to [email protected] no matter how trivial.
Refers to useful information for the optimal operation of the system
Indicates a SAFETY issue that is likely to cause injury or death if the user does not
follow the instructions.
Indicates a SAFETY issue that may cause injury or death if the user does not follow the
instructions.
Indicates a SAFETY issue that may cause injury or property damage if the user does
not follow the instructions
Refers to critically important information related to the correct functioning of the
system.
Why? Italic text is optional reading. Gives extra information and reasoning for recommendations that are
non-obvious and/or counter intuitive.

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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2Pre-Installation Suitability and Safety Checklist
The following outlines mandatory suitability and safety requirements for installing this solar heating system. Please
read carefully, if any of the following requirements cannot be meet the system should NOT be purchased or
installed.
Due to the potential of falling from heights, mounting the solar strip collectors on a roof or
structure at heights should only be undertaken by a professional installer, unless you are
accustomed to and confident of performing the work safely. We strongly recommend the
installer invests in roof safety guard rails and a safety harness system, especially for DIY
applications.
Building regulations vary from state to state and MUST override any instructions supplied in
this manual. It is the responsibility of the purchaser/installer to check that installations
comply with any relevant state laws and regulations.
Collectors are to be used with chlorinated (or otherwise sanitized) pool water ONLY. Do not
use collectors to heat fresh (untreated) water due to the potential for Legionaries bacteria
build up.
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been
given supervision or instruction concerning use of the appliance by a person responsible for
their safety. Children should be supervised to ensure that they do not play with the appliance.

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 6
3Warranties
EcoOnline™ offers the following Warranties
15 Year pro-rata Warranty on all strip collectors
2 year Warranty on Reltech Pool Pumps
3 year Warranty on Davey Pool Pumps
3 Year Warranty on Dontek and Ascon Controllers
See our Terms and Conditions page for further details: www.EcoOnline.com.au/terms-and-conditions
4Collector Sizing Guide
An interactive collector sizing calculator and pool water temperature simulator can be found on our website at:
www.EcoOnline.com.au/pool-heating-sizing-calculator
www.EcoOnline.com.au/pool-water-temperature-simulator
4.1 A Word on Transparent Bubble Pool Covers
EcoOnline recently carried out a full pool heating loading technical study including performance data on transparent
bubble pool covers. We found that while pool covers produce a moderate heating effect by themselves, they
produced a much larger pool temperature boost when used in conjunction with a solar pool heater due to
synergistic effects. So much so that if you’re running a solar pool heater and not using a pool cover you are missing
out on surprisingly large temperature gains - see link below for the summaries:
www.EcoOnline.com.au/how-warm-can-a-pool-get-with-a-solar-heater-and-cover
So if you’ve used a pool cover before and had disappointing results, we highly recommend you try using a cover
again after you install our solar pool heating system.
Customer please note: WARRANTY IS VOID if collectors are installed:
without a vacuum release valve on the return line,
or a non-return valve on the solar pump outlet (with 6mm drain hole in flap),
or without a by-pass valve on a grossly oversized pump,
or with water pH less than 7.2,
or without the supplied strainer (for systems independent of the main filter),
or if the collectors are installed below the water level.
Why? Such installations will expose the collectors to debris build up, strong fatiguing
positive/negative pressures and/or chemical attack from hot water. These situations will
have detrimental effects on the collectors which will limit lifetimes.

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 7
5Pool Chemistry Compatibility Guide
6Pump Sizing Guide
6.1 A Word on Pump Sizing Choice
The quick reference tables below outline conservative Australian Standard pump sizing recommendations.
There is a range of pump powers one can choose from. If thermal system efficiency is important then choose a pump
at the high end to produce high flow rate; take care not to over-pressurizing your system (see Optimizing Collector
Pressure below). If electrical efficiency (COP factor) is important to you then choose a pump near the lowest power
range. To help you understand the potential savings from this choice we have created an interactive pump sizing
simulator which can be found on our website at:
www.ecoonline.com.au/poolmasterpro-strip-pool-heating-pump-sizing
However, if you go with a lower power pump you’ll need the following:
A slightly larger collector area; the pump sizing calculator will let you know by how much.
You will need to check with the pump manufacture that your chosen pump can still prime reliably at your
pump height.
We highly recommend you use a by-pass line to help your pump to prime reliably, see Installing a By-Pass
Tube or By-Pass Ball Valve below.
Lastly you may need to run your main filter pump in the afternoon to help mix the warm water if your pool
volume turnover falls below the 50% - 75% range.
6.2 Quick Reference Solar Pump Sizing for Independent Systems
The two tables below will give you the minimum and maximum Australian Standard pump power recommendations
for independent type systems in input watts (not output watts), these specs should be marked on the pump.
Minimum Recommended Pump Power is Limited by Water Turn-Over Requirements
Pool
Water Volume
Minimum
Recommended Flow
For 1st Story Install (3m):
Minimum Input Watts Required
For 2nd Story Install (6m):
Minimum Input Watts Required
20,000 L
50 L/min
270 Watts (0.36 HP)
350 Watts (0.47 HP)
25,000 L
63 L/min
290 Watts (0.39 HP)
370 Watts (0.50 HP)
30,000 L
75 L/min
320 Watts (0.42 HP)
400 Watts (0.53 HP)
35,000 L
88 L/min
340 Watts (0.46 HP)
420 Watts (0.56 HP)
40,000 L
100 L/min
370 Watts (0.49 HP)
450 Watts (0.60 HP)
45,000 L
113 L/min
390 Watts (0.52 HP)
470 Watts (0.63 HP)
50,000 L
125 L/min
420 Watts (0.56 HP)
500 Watts (0.67 HP)
This system is not compatible with acidic pool/spa water (pH less than 7.2). Sodium
Carbonate must be added to protect the system from acidic pH (<7). pH should be maintained
between 7.2-7.8 for maximum system longevity.
Why? Acidic water with pH less than 7.0 has excess free H+ ions which like to bond to and
hence break apart polymer carbon and silicon bonds.

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
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55,000 L
138 L/min
450 Watts (0.60 HP)
530 Watts (0.71 HP)
60,000 L
150 L/min
470 Watts (0.64 HP)
560 Watts (0.75 HP)
65,000 L
163 L/min
500 Watts (0.68 HP)
590 Watts (0.79 HP)
70,000 L
175 L/min
530 Watts (0.72 HP)
620 Watts (0.83 HP)
75,000 L
188 L/min
570 Watts (0.76 HP)
660 Watts (0.88 HP)
80,000 L
200 L/min
600 Watts (0.80 HP)
690 Watts (0.93 HP)
If you don’t know your pools water volume you can look it up from the table supplied below based on the total
water area and average depth:
Maximum Recommended Pump Power is Limited by Collector Pressure
Collectors
Gross Area
Maximum
Recommended Flow
For 1st Story Install (3m):
Maximum Input Watts
For 2nd Story Install (6m):
Maximum Input Watts
13 m2
67 L/min
340 Watts (0.47 HP)
450 Watts (0.61 HP)
17 m2
83 L/min
380 Watts (0.51 HP)
480 Watts (0.65 HP)
20 m2
100 L/min
410 Watts (0.55 HP)
520 Watts (0.69 HP)
23 m2
117 L/min
450 Watts (0.60 HP)
550 Watts (0.74 HP)
27 m2
133 L/min
490 Watts (0.65 HP)
590 Watts (0.79 HP)
30 m2
150 L/min
530 Watts (0.70 HP)
630 Watts (0.85 HP)
33 m2
167 L/min
570 Watts (0.76 HP)
670 Watts (0.90 HP)
37 m2
183 L/min
610 Watts (0.82 HP)
720 Watts (0.97 HP)
40 m2
200 L/min
660 Watts (0.88 HP)
770 Watts (1.03 HP)
43 m2
217 L/min
700 Watts (0.94 HP)
820 Watts (1.10 HP)
47 m2
233 L/min
750 Watts (1.00 HP)
870 Watts (1.17 HP)
50 m2
250 L/min
800 Watts (1.08 HP)
930 Watts (1.24 HP)
53 m2
267 L/min
860 Watts (1.15HP)
980 Watts (1.32 HP)
6.2.1 Example Pump Sizing
For example, for a large 75,000 Litre pool and 1st story roof your minimum Australian Standard pump specs from
the first table above are 566 Input Watts. If you want to install a 40 m2collector area for this pool for example, your
Pool Water area vs Average Depth Conversion Table
Average depth
Waters Area
1.3 m
1.4 m
1.45 m
1.5 m
1.55 m
1.6 m
1.65 m
1.7 m
1.8 m
10 m2
13000 L
14000 L
14500 L
15000 L
15500 L
16000 L
16500 L
17000 L
18000 L
15 m2
19500 L
21000 L
21750 L
22500 L
23250 L
24000 L
24750 L
25500 L
27000 L
20 m2
26000 L
28000 L
29000 L
30000 L
31000 L
32000 L
33000 L
34000 L
36000 L
25 m2
32500 L
35000 L
36250 L
37500 L
38750 L
40000 L
41250 L
42500 L
45000 L
30 m2
39000 L
42000 L
43500 L
45000 L
46500 L
48000 L
49500 L
51000 L
54000 L
35 m2
45500 L
49000 L
50750 L
52500 L
54250 L
56000 L
57750 L
59500 L
63000 L
40 m2
52000 L
56000 L
58000 L
60000 L
62000 L
64000 L
66000 L
68000 L
72000 L
45 m2
58500 L
63000 L
65250 L
67500 L
69750 L
72000 L
74250 L
76500 L
81000 L
50 m2
65000 L
70000 L
72500 L
75000 L
77500 L
80000 L
82500 L
85000 L
90000 L
55 m2
71500 L
77000 L
79750 L
82500 L
85250 L
88000 L
90750 L
93500 L
99000 L

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 9
maximum pump specs, from the second table above are 656 Input Watts. Pumps well below the minimum specs
may not be strong enough to turn over a sufficient volume of water - while oversized pumps are more expensive to
run for little extra heat gain and may need a ball valve constriction installed depending on the collector’s internal
pressure.
6.3 Solar Pump Sizing for Booster Systems
6.4 Filter Pump Sizing for Manual Systems
7Solar Line PVC Pipe Sizing Guide
The table below will help you choose the correct size PVC pipe for the solar lines running to and from your roof. On
the roof we generally recommend 40 PVC (DN40) to match the manifolds. Coming down the roof the pipe size can
then be adapted to the pipe size you have for your solar line ground run i.e. 40 PVC (DN40) or 50 PVC (DN50).
Recommended PVC Piping Sizing for Solar Pool Heating System Lines
Anticipated Flow Rate
Absolute Minimum
Ideal PVC Pipe Size
Maximum Pipe Size
70 Litres/min
20 PVC (DN20)
25 PVC (DN25)
32 PVC (DN30)
120 Litres/min
25 PVC (DN25)
32 PVC (DN30)
40 PVC (DN40)
200 Litres/min
32 PVC (DN30)
40 PVC (DN40)
50 PVC (DN50)
250 Litres/min
40 PVC (DN40)
50 PVC (DN50)
65 PVC (DN65)
400 Litres/min
50 PVC (DN50)
65 PVC (DN65)
80 PVC (DN80)
880 Litres/min
80 PVC (DN80)
100 PVC (DN100)
125 PVC (DN125)
For booster type systems you should choose a pump at or just below the minimum
specs in the table above. Why? The take off point for solar is already pressurized by the
filter pump, hence a smaller pump should be used.
For manual type systems running off a main pool filter pump, please check that the filter
pump is large enough to accommodate the extra load of supplying water to the collectors
at the required pump height + a 1 meter pressure drop across the collector array. Why?
Filter pumps are geared for flow, not pump height, solar pumps are geared specifically for
roof solar applications.
If the distance from the pool to the roof collector area is more than 10m we recommend
you use the next size up PVC pipe.

PoolMasterpro™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 10
8Collector Array Components
1 × 4m2Strip Collector Kit (number of kits depends on system purchased)
1× 25m 14 tube PVC
nitrile 165mm
strip role
2× 40 PVC (DN40)
PVC Manifold -
500mm x 14 Tube
28 × tube locking
collars
1× silicon tube
per 4m2kit
1 × Pipe clamp +
0.5m band for
fixing per 4m2 kit
Other Essential System Components (depending on system purchased)
1 × 32/40 PVC
Vacuum breaker
valve
1 × Can of
silicon lubricant
spray
1 × Drain Down
Kit
2 ×28 locking
collar for
repair kit
1 × 14 joining
barb repair
kit
1 × In-line
pressure gauge
For Manual Systems (depending on purchase)
For Independent Systems (depending on purchase)
1 × 40 PVC (DN40) PVC 3-
way Ball valve
1 × 40 PVC (DN40) Spring
loaded non-return valve
1 × Dontek Controller
1 × 40 PVC (DN40) PVC
strainer