Optex Solar Eco Online User manual

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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EcoOnline™
Solar Pool Heating System Manual
Installation and User Manual - Revised 25/11/2013
© Copyright 2012 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.
Optex Solar Pty. Ltd.
www.EcoOnline.com.au
email: [e-mail]

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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Contents
1 Key Terms.................................................................................................................................................................. 3
2 Pre-Installation Suitability & Safety Checklist........................................................................................................... 4
3 Warranties ................................................................................................................................................................ 5
4 System Sizing Guarantee........................................................................................................................................... 5
5 Collector Sizing Guide ............................................................................................................................................... 5
6 Pool Chemistry Compatibility Guide ......................................................................................................................... 6
7 Roof Type Compatibility Guide ................................................................................................................................. 6
8 Wind and Climate Considerations............................................................................................................................. 7
9 PVC Pipe and Pump Sizing Guide .............................................................................................................................. 7
10 Collector Array Components..................................................................................................................................... 8
11 Additional Required Components (Not Supplied) .................................................................................................... 9
12 Required Tools ........................................................................................................................................................10
13 Safety When Working at Heights............................................................................................................................11
14 Ladder Safety ..........................................................................................................................................................11
15 Choosing a Place to Install the Collector Array....................................................................................................... 12
16 Collector Array Configurations................................................................................................................................ 13
17 Roof Attachment Options ....................................................................................................................................... 17
18 Collector Mounting Procedure ............................................................................................................................... 21
19 Collector Array Plumbing Connections ................................................................................................................... 22
20 Roof Fixing Configurations ...................................................................................................................................... 23
21 Wind Proofing .........................................................................................................................................................28
22 Plumbing .................................................................................................................................................................31
23 Frost Proofing and Winterization............................................................................................................................ 34
24 Optimizing Collector Pressure................................................................................................................................. 34
25 Checking for Balanced Water Flow through All Collectors ..................................................................................... 36
26 Service and Maintenance Schedule ........................................................................................................................36
27 Important Installation Check List ............................................................................................................................ 37

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 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:
This manual was written to follow guidelines and recommendations given in:
AS 3634 - 1989 Solar heating systems for swimming pools
AS 1170.2 - 2011 (Amend 2 Dec 2012) Structural design actions - Wind actions
‘HAZPAK’ produced by the work-cover authority
AS 3000 (2007) Sections 6.3, 6.4 & 6.5
AS 1926.1 & 1926.2 (2007) swimming pool safety - location of safety barrier
Please take the time to read both manuals 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.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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2Pre-Installation Suitability & 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.
For ground level collector installations the installer MUST check child safety fence regulations
in the relevant state. Under no circumstances should collectors be installed so as to
compromise the effectiveness of a child pool or spa fence safety barrier by providing a
climbable object.
Due to the potential of falling from heights, mounting the solar panels on a roof or
structure at heights should only be undertaken by a professional solar panel installer,
unless you are accustomed to and confident of performing the work safely.
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.
At present this collector array system is not recommended for installations in cyclonic
regions C or D, or on houses situated on top of hills exposed to strong winds, or on second
story (or higher) roofs. Installations on tiles are for Wind Region A only.
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.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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3Warranties
EcoOnline™ offers the following Warranties
5 year limited Warranty on all HDPE collectors
2 year Warranty on Reltech Pool Pumps
3 year Warranty on Davey Pool Pumps
2 Year Warranty on Dontek Controllers
See EcoOnline.com.au Terms and Conditions page for further details.
4System Sizing Guarantee
Sizing systems is difficult involving a lot of factors which we could get wrong. Hence in addition to the above
Warranties EcoOnline offers a System Sizing Guarantee as follows. If we sized your system (or you use our online
calculator) and you took our advice and you aren’t happy with the systems performance (heat output), then you can
purchase up to 25% more panels originally supplied by EcoOnline up to two years after your original purchase and
we will ship the items free of shipping charges.
5Collector Sizing Guide
An interactive collector sizing calculator can be found on our website at,
http://www.EcoOnline.com.au/product-information/solar-pool-heating/sizing-guide
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 with a grossly oversized pump,
or in a manner that prevents collector from fully draining when the pump stops.
Why? Such installations will expose the collectors to strong fatiguing positive/negative
pressures, and/or stagnant hot chlorinated water on hot days. These situations will have
detrimental effects on the collectors which will limit lifetimes and can also result in
significant shrinkage of the collectors which would put strain on roof attachments means.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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6Pool Chemistry Compatibility Guide
Incompatible Chemistries
Alternatives Chemistry
✘Bromide Based Chlorination
✔Any other Chlorination or Sanitation
✘Hydrochloric Acid
✔Sodium Bisulphate Acid
✘Acidic Water (pH less than 7.2)
✔Water pH greater than 7.6
7Roof Type Compatibility Guide
Roof Type
Peak to Valley Measure
Recommendation
Standard Corrugated Iron roof (Custom Orb)
17mm
Okay
Relatively Flat Tile roof
Less than 25mm
Okay
Spandek Iron roof
24mm
Okay
Modulated Tile roof
Greater than 25mm
Region A Only
Trimdek Iron roof
29mm
Region A Only
Klip-lok Iron roof
43mm
Not Recommended
Flatdek Iron roof
45mm
Not Recommended
If panels are to be installed on a roof then the following should be observed to limit wind
uplift potential.
1) Installed panels should lay flat touching the roof structure. It is recommend the air
gap distance between the bottom of the installed collector and the valley points of
the roof corrugations should be no greater than approximately 25mm.
2) Panels should have adequate clearance from roof edges.
3) Panels on roofs should not be mounted on tilt frames.
Why? The average air gap distance between the mounted collector and roof structure has a
strong influence on wind loadings. Furthermore due to roof edge turbulence effects wind
loadings are highest near roof edges.
This system is not compatible with bromide chlorination, hydrochloric acid use and/or 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.
If absolutely required Sodium Bisulphate acid can be used to keep the pH down.
Why? Acidic water with pH (less than 7.0) has excess free H+ ions which like to bond to and
hence break polymer carbon and silicon bonds.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
Page 7
8Wind and Climate Considerations
9PVC Pipe and Pump Sizing Guide
We recommend that PVC pipe and the water flow rate for the solar pool heating system be sized according to the
pools water volume. The table below will help you choose the correct size PVC pipe for the solar lines running to and
from your roof.
Recommended PVC Pipe & Pump Sizing for Solar Pool/Spa Heating Systems
Your Pool/Spa
Size
Recommended
PVC Pipe Size
Flow Rate at Pump Height:
(Min –Max)
Pump Sizing:
(Single Story Install)
up to 2,500 L
20 mm
10 –20 Litres/min
0.08 HP (60W solar)
up to 5,000 L
20 mm
15 –30 Litres/min
0.08 HP (60W solar)
up to 11,000 L
25 mm
20 –40 Litres/min
0.25 HP (200W)
up to 22,000 L
32 mm
40 –80 Litres/min
0.3 HP (300W)
up to 37,000 L
40 mm
60 –120 Litres/min
0.3 HP (400W)
up to 60,000 L
40 mm
100 –200 Litres/min
0.5 HP (500W)
up to 77,000 L
50 mm
125 –250 Litres/min
0.5 HP (600W)
up to 120,000 L
80 mm
200 –400 Litres/min
1.0 HP (750W)
up to 260,000 L
100 mm
425 –880 Litres/min
1.5 HP (1500W)
When installing a solar pool heating system, it is imperative to check whether the
pump will provide the required water flow rate at the pump height of the
installation.
Panels installed above the roof structure with 50mm or greater underneath air gaps experience
much higher wind loadings and are now subject to the Australian wind loading standard
AS/NZD 1170.2.
It is the responsibility of the installer to consider wind loading factors, see “wind proofing”
section below. If the installation site is within strong wind speed areas then the extra
stainless steel guide line must be installed across each row with the in-between panel
anchor points. Do not assume supplied components are sufficient.
sufficient.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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10 Collector Array Components
Interconnect OR Dual Header Panel Kit:
1 × HDPE interconnect panel
1 × HDPE dual header panel
You should also check
that your pump does
not exceed the
maximum
recommended 3m/s
water flow velocity for
PVC piping. Check
table to the right.
Maximum Recommended Flow Rates for PVC Pipe (3m/s)
PVC Pipe Size
Maximum Flow Rate
20 mm
70 Litres/min
25 mm
120 Litres/min
32 mm
200 Litres/min
40 mm
250 Litres/min
50 mm
400 Litres/min
80 mm
880 Litres/min
If you need to create solar inlet/outlet suction piping for your pool you should note that AS
3634-1989 recommends a maximum water velocity of 1.8m/s for this section of pipe. Please
consult your pool builder.
Do not expose the collector array to pressures greater than 16 psi (110kPa). Note: if for
whatever reason water flow is fully blocked, a pump with a 15 meter head pressure will
generate 150kPa at ground level, 100kPa at 5m and 50kPa at 10m.
Why? Plastic longevity is strongly dependent on pressure fluctuations and temperatures.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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11 Additional Required Components (Not Supplied)
You also require some of the following extra items depending on your system. These are available in any plumbing
store. The aluminium angle is available from Capral Ltd. or Ullrich Aluminium Pty. Ltd.
1 × 40mm reinforced silicon joiner
1 × 25mm reinforced silicon joiner
4 × Stainless steel hose clamps
3 × 316 Stainless steel straps (black)
1 × 50cm length perforated 316 stainless band
2 × 40mm reinforced silicon joiners
4 × Stainless steel hose clamps
6 × 316 Stainless steel straps (black)
1 × 25cm length perforated 316 stainless band
Other Collector Array Components
1 × 32mm/40mm PVC Vacuum breaker valve
(MUST be installed)
2 × 40mm hose barb to 25mm/32mm
PVC glue socket/take off
Roof Mounting (Solar roof hook supplied only if requested and purchased)
1 × 304 Stainless solar roof hook (height adjustable)
Dimensions: A = 47.5mm,B = 117.5mm,C = 60mm

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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12 Required Tools
- Battery powered hand drill with 8mm Hex socket - Screwdriver with 8mm socket fitting
- Silicon gun and clear silicon sealant - PVC pipe saw
- PVC glue - Level
- Teflon tape
- Industrial Ladder
30-32mm x 30-32mm x 3-
4mm Aluminium angle
4mm stainless steel cable
& four cable ties per row
PVC 25-40mm (PN12)
piping
PVC 25-40mm PVC bits
We recommend AS 1477 compliant PVC 25-40mm piping with PN12 pressure rating or
greater and matching PVC fittings be used for all collector array plumbing.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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13 Safety When Working at Heights
The installer should always take the necessary safety precautions:
Choose an appropriate day: cool, dry, calm and partly cloudy.
Plan out your install: make sure you have all required components, tools and have plenty of allocated time.
Only work at heights when you are well rested and alert.
Never work alone, always work with at least one other person.
Always use a safety harness or fall arrest system attached to appropriate roof anchor points.
Wear clothes that fit well but that do not restrict movement.
Use proper non-slip shoes.
Use sunscreen.
14 Ladder Safety
The chance of a falling from a ladder should never be
underestimated. Use only solid industrial grade ladders in good
repair that have been checked for faults.
Note: even a small unexpected movement of the ladder, such as a
small slip, can cause loss of balance and result in a fall.
The ladder should be placed on solid ground and should ALWAYS be
securely anchored at the base and secured at the top to prevent
slipping.
WHEN WORKING AT HEIGHTS - SAFETY COMES FIRST. A person can easily fall off a ladder
or roof and be seriously injured. For installations on a roof pitch greater than 22° and/or a
double story house we strongly recommend a highly competent professional installer install
your solar collector array. The installer MUST use an appropriate safety harness.
Solar panels should not be mounted in windy or gusty conditions; a panel can easily be caught
in the wind and cause a loss of balance and result in a fall.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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15 Choosing a Place to Install the Collector Array
When choosing a location for your collector array you should consider:
Shading - the collector array should receive no shading between the hours 10am to 4pm.
Wind - the collector array should be mounted in a relatively sheltered location or with appropriate wind
proofing.
Distant to pool/spa - collectors should be as close as possible to your pool (or spa).
Direction - collectors should preferably face northwest for maximum heat collection; however the collector
array can also face any angle between Northeast to West.
Mounting elevation - this depends on the desired seasonal heat collection. Flatter elevations (< 45°) collect
more heat in the summer while installations closer to vertical (> 45°) produce more heat during
spring/autumn.
The figure to the left shows an example of a Child Safety
Barrier marked with a dashed line. A collector array
should not be mounted near the Child Safety Barrier -
both on the inside and outside of the Pool Area unless
proper clearances are observed. Consult your Local
Government, The Building Commission or SPASA for
details regarding pool safety barriers in your state.
Please keep up to date with regulations as they change
over time. For more information see, AUSTRALIAN
STANDARDS 1926.1 2007 AND 1926.2 2007 FOR POOL
SAFETY BARRIERS.
Do not install the collectors leaning against the
outside of a Child Safety Barrier so as to create a
climbable object for children to access the pool or spa.
Collectors installed inside the pool area in front
of a boundary fence must be offset away from the
boundary fence with the proper clearance from the top
of the fence so as not to provide a foothold for a child climbing into the pool area.
Do not install the collectors too close to the inside of a Child Safety Barrier so as to provide foot or
handholds from the outside of the barrier.
For spa baths and above ground pools do not lean the collector array against the side of the spa or pool so as
to create a ramp or climbable object.
For ground mounted arrays, under no circumstances should a collector array be mounted in
anyway so as to compromise the effectiveness of a pool or spa Child Safety Barrier.
The collector array can face anywhere from West to North-east, with an optimal
orientation of North-west for most areas. All other orientations are not recommended.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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16 Collector Array Configurations
16.1 Dual Header Panel Array Configurations

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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16.2 Interconnect Panel Array Configuration
16.3 Ground Mounted Collector Array Configuration
For ground mounted arrays, under no circumstances should a collector array be mounted in
anyway so as to compromise the effectiveness of a pool or spa Child Safety Barrier.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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16.4 Split Collector Array - Similar Level Configuration
16.5 Split Collector Array - Higher Level Configuration
Split collector arrays should be installed facing the same direction - or have no more
than 30˚ compass facing difference between them. In this later case the temperature
sensor should be installed at an angle that is an average of the two collector array
compass facing directions.
Why? Depending on the location of the roof sensor the controller could turn the system
on with one bank of collectors in full shade.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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16.6 Recommended Return Line Configuration for Low Roof Pitch (2.5˚ - 5˚)
16.7 Bi-Directional Arrays
Collector arrays that face opposing compass directions are not recommended unless
the roof pitch is less than ~15˚. In this case the temperature sensor should be installed
at an angle that is an average of the two collector array directions.
Why? Depending on the location of the roof sensor the controller could turn the system
on with one bank of collectors in full shade.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
Page 17
16.8 Plumbing Configurations Not Recommend
17 Roof Attachment Options
Note the high thermal contraction and natural relaxation of HDPE:
Collectors will contact (in length) by up to 10mm over time and 12mm thermally across
temperature extremes. Hence any fixing means must account for an ultimate contraction of
22mm in length per panel.
Key design principles when choosing a roof mounting means:
1) Consider the high thermal contraction of HDPE
2) Panels should be as low down on the roof as possible to prevent the wind from
catching the underside of panels.
3) The stainless steel straps should not be used to support loads, only as security against
excessive wind speeds.
To make sure all air bubbles are evacuated upon filling collector MUST be installed
with a minimum recommended pitch of 5˚.
Ideally the collector array top header pipe should have a 1 to 2° upward slope toward
the outlet. This is to make sure all air is automatically removed from the entire array
upon filling.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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17.1 Tile Roof Mounting Frame
For tile roofs we recommend using a minimum roof hook spacing of 600mm in the top and
bottom row. Depending on your wind loading (see “Wind Proofing” section), angle of install
and the dead weight of the collectors, you may require a higher density of roof hooks and/or
a stronger Aluminium L-angle, if unsure please seek advice.

Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
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Eco Online™ Solar Pool Heating System -- Installation Manual
© Copyright 2012 Optex Solar Pty Ltd. All rights strictly reserved.
Page 20
17.2 Corrugated Metal Roof Mounting Frame
For metal roofs we recommend using a minimum roof hook spacing of 600mm in the top and
bottom row. Depending on your wind loading (see “Wind Proofing” section), angle of install
and the dead weight of the collectors, you may require a higher density of roof hooks and/or
a stronger Aluminium L-angle, if unsure please seek advice.