Sundware Solar Pool System User manual

Solar Pool Heating Systems
Installation Manual

Table of Content
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Pipe and Pipe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Cleaner and Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Panels and Installation Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6 Solar Collector Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
7 Solar Pool Heating Systems Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.1 BeforeYou Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.2 Array Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.3 Space Required For Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
8.4 Flow Rate through Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.5 Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
8.6 Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
8.7 Piping Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
8.8 Layout of the Solar Panel Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
8.9 Solar Panels.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
8.10 Assemble the Solar Panel Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
8.11 Mounting the Solar Panel Array. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
8.12 Flat Roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
8.13 Ground Mounting Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
8.14 Plumbing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
8.15 Plumbing Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
9 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Pipe Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11 Pipe Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12 Control installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.1 Solar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
12.2 TypicalAutomatic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
12.3 System Check Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12.4 TypicalAutomatic Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
12.5 Typical Control Operating (Les fonctions du ControleAutomatique) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13 Special Roof Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14 Operating and Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
15 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
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Installation Manual
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1. Introduction
Before attempting installation, read the instructions in this manual carefully. This manual contains
easy to follow step-by-step procedures to property install our Techno-Solis pool solar system. Your
understanding our system and it parts will assure a successful, trouble-free installation. If you have
any product or installation questions regarding this installation, contact our representative at your
nearest area.
It is important to recognize that this manual outlines the recommended installation methods and
practices as prescribed by the factory. It is designed to aid the installer or even the novice through
providing optimum protection for the products. Also, these are the minimal requirements; addition-
al protection may be required in hazardous environments or in areas subject to extremes of weather.
In those areas, the local expertise of the contractor may be relied upon in coordination with our ap-
proval for special installation considerations.
Take time to read through this manual. It will guide you through the most ecient way to correctly
install our pool solar system. By following this step by step guide, your system will meet the instal-
lation standards recommended by the factory. In addition, because we’ve included techniques and
tips gathered from experienced SUNDWARE contractors throughout the countries, using this instal-
lation will save you time and eort.
2. Getting Started
Before you begin your installation, here are a few important advices:
1. Caution- Safety Comes First !!!!
• There is no substitute for safety. Always exercise extreme caution, care and good jud
ments when working on or around a roof or pool area.
• Please take care to avoid hazards such as over-head electrical wires or loose shingles or
roof tiles.
• Be sure to secure ladders so they will not slip or fall.
• Do not allow extension cords to lie in the pool or in standing water.
• Wear shoes with proper tread to prevent slipping on the ladder or sloped roof areas.
• Disconnect all power to the pool equipment when installing an automatic control
system.
2. Before starting any work, determine the location of your system and prepare a schematic
drawing of the installation area. Include the location of the feed and return lines in this
drawing. Roof areas often times look bigger than they really are, so be sure to measure the
available area before making your schematic.
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3. The planned placement of the panels should allow the panels to drain when the pool pump
shuts o.
4. The paint of the outdoor pipes and ttings should be UV resistant. Painted pipes and ttings
will require additional maintenance.
5. Never walk on collectors when they are wet as they present a signicant slip hazard. Walking
on the collectors should only take place when absolutely necessary.
6. Familiarize yourself with all of our pool solar components and plumbing materials that are
needed to complete the installation.
3. Pipe and Pipe Fittings
Use pressure rated Schedule 40 PVC pipe. You may prefer to use black, but because black PVC
can be dicult to nd, some installers have inquired about the use of black ABS pipe instead. DO
NOT USE ABS PIPE. ABS pipe does not have the UV inhibitors that PVC pipe has, causing ABS pipe
to become brittle and to crack after several years of exposure.
Use PVC Schedule 40 pressure-rated fittings to match your PVC pipe. Be sure NOT TO USE
“plumbers” fittings or DWV fittings (drain, waste and vent).
4. Cleaner and Cement
Refer to the product’s label for selecting good quality Cleaner and CPVC all-purpose cement.
Before applying the cement, be sure to clean each fitting and pipe end with the PVC Cleaner
or “primer.” Soon after cleaning each part, apply ample cement first to the fitting and then to the
pipe end. Insert the pipe end into the fitting with a slight twisting motion until it seats to evenly
distribute the glue. Hold it in this position for 5 to 10 seconds to allow the joint to set up. Finally,
wipe excess cement off of the joint and pipe.
Note: Cold weather slows the set-up process for PVCglue. If installing in colder climates, refer to the
PVC glue manufacturer’s charts for curing times.
5. Panels and Installation Kits
Planning ahead and having the proper partsand kits for your system will make your installation
much easier. The kits and parts that are useful for our systems are shown here below under the
title “PARTS LIST”.
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Installation Manual
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1. Necessary items:
A) SOLAR PANELS :
C15TS12 SOLAR PANEL 4’ x 12’
or C15TS10 SOLAR PANEL 4’ x 10’
or C15TS08 SOLAR PANEL 4’ x 8’
B) KITS :
K15 SYSSYSTEM KIT
(one per system) includes :
2 A15ADAPipe to panel adap. PVC 1 ½”x3” lg.
5 ALAGScrew ¼” x 2” lg. and washer
1 ARS-SILCaulking silicone
1 F20BSTRAP2”- black steel“U” support
2 K15BCAPEnd cap kit 1 ½”
K15 PANPANEL KIT
(one per system) includes :
2 A15HOSEPDM hose 1 ½”
4 AGC32Gear clamp #32
5 ALAGScrew ¼” x 2” lg. and washer
1 F20BSTRAP2”- black steel“U” support
½ ASTR29PPolyester strap roll (29 pi.)
K15PBWPIPING KIT PVC 1 1/2”
(one per system) includes :
1 AGC32Gear clamp #32
1 AGLUE1/2PT PVC glue #711
24 ALAGScrew ¼” x 2” lg. and washer
6 F15B901 1/2” PVC black 90° elbow
2 F15BCOU1 1/2”PVC black straight coupling
4 F15BSTRAP1 1/2” black steel“U” support
1 F15CORL/S1 1/2”PVC adaptor corlon/slip
10 F15W901 1/2” PVC white 90° elbow
1 F15WADA-M 1 1/2” PVC white male adapt.
4 F15WCOU1 1/2”PVC white straight coupling
8 F15WSTRAP 1 1/2” white steel“U” support
1 F15WTEE1 1/2” PVC white tee
40 P15B(ft.) 1 1/2” PVC black pipe
60 P15W(ft.) 1 1/2” PVC white pipe
C) CONTROLS
K15CTRMMANUAL CONTROL KIT
(one per system) includes :
1F15V21 1/2” PVC ball valve
1F15VCHECK 1 1/2” PVC check valve
1F15WTEE1 1/2” PVC white tee
1F15WU1 1/2” PVC white union
or
K15CTRAAUTO. CONTROL KIT
(one per system) includes :
4C-3MWire nuts
1C-FV2.03 way motorized valve PVC 2”
1C-HM4000HM4000 control box
1C-PSPool sensor #1S 1.0-10K
1C-RSRoof sensor #AS2-10K
10 C-TYETy-wrap 11” lg.
100 C-WIRE(ft.) Shielded wire #2-18
1F15VCHECK 1 1/2” PVC check valve
1F15WU1 1/2” PVC white union
3F20WRED152”x1 1/2” PVC red. bushing
2. Optional items :
K15BKBBANK KIT 1 1/2”
includes :
2A15ADAPipe to panel adap. PVC 1 ½”x3”lg.
5ALAGScrew ¼”x 2” lg. and washer
2F15B901 1/2” PVC black 90° elbow
1F20BSTRAP2”- black steel “U” support
2K15BCAPEnd cap kit 1 ½”
K15SPLBSPLIT KIT 1 1/2”
includes :
4A15ADAPipe to panel adap. PVC 1 ½”x3”lg.
2A15HOSEPDM hose 1 ½”
4AGC32Gear clamp #32
5ALAGScrew ¼”x 2” lg. and washer
4F15BCOU1 1/2”PVC black straight coupling
1F20BSTRAP2”- black steel “U” support
K15UNGUNDERGROUND KIT
includes :
4 AGC32Gear clamp #32
4 F15CORL/90C 1 1/2” PVC 90° elbow corlon/glued
4 F15CO1 1/2” DVW clean-out
4 F15WTEE1 1/2” PVC white tee
PARTS LIST
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Installation Manual

6. Solar Collector Layout
The most common solar collector installations are shown below:
Note: No more than two (2) arrays are allowed in series feed and no more than eight (8) collec-
tors are allowed in each array.
Fig (1): Single Row
Fig (2): Double Row
Fig (3): Single Row Spit Feed
Fig (4): Series Feed
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Installation Manual
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7. Solar Pool Heating Systems Components
Fig (5): Techno-Solis Solar Pool Heating System Components
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Installation Manual

The Solar pool system has the following components (see gure 5)
1. The SUNDWARE PANELS are the key to your system. They absorb the sun’s heat eciently
and transfer the energy to the swimming pool water that is pumped through them.
2. The SOLAR ROOF SENSOR* is installed beside the SUNDWARE solar panels to sense the
heat from the Sun. It relays the solar panel temperature to the automatic control.
3. The POOL WATER SENSOR* is installed in the pool plumbing, after the lter. It senses the
pool water temperature and relays the information to the automatic control.
4. The AUTOMATIC CONTROL and MOTORIZED 3-WAY VALVE* compare the pool water tem-
perature to the solar roof temperature to turn the SUNDWARE solar heating system on or
o, as required.
5. The existing PUMP and FILTER circulate clean water to the pool and through the solar
panels when required.
6. The END CAPS seal the solar panel headers at the end of the row.
7. The LAG SCREWS and WASHERS are used to secure mounting straps to the roof.
8. The MOUNTING STRAPS are used with lag screw and washer to secure the solar panels to
the roof.
9. The EPDM HOSES connect the SUNDWARE solar panels together and connect the piping
to the solar panel array.
10. The CHECK VALVE* is used to prevent backow circulation in the solar panels at night.
(1/8” diameter hole to be drilled in the apper to allow for winter drainage).
11. The “U”STEEL SUPPORTS are used to anchor the top header of the solar panels.
* Only used in systems with automatic control.
Some systems will use a manual valve for turning the system on or o.
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Installation Manual
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8. Installation
8.1 Before You Start
Please read the complete manual before starting. If you have any installation problems or ques-
tions, consult SUNDWARE GROUP’ distributor. Remember, serious damage may result from mal-
function of the system and its components if instructions are not closely followed.
Check local plumbing, electrical and building codes. The installation must comply withthe local
regulations, which vary substantially from location to location.
8.2 Array Size
The number of solar panels required in the array is primary dependent upon the surface area of
the pool and the amount of solar energy available in the area of the installation.
The relationship between solar panel area and pool area should be: (for summer heating).
50% if solar panels are SOUTH facing
75% if solar panels are WEST facing
80% if solar panels are EAST facing
75% if solar panels are laid at (with a minimum of 10 degrees inclination for properdrainage)
8.3 Space Required For Array
The minimum linear space for an array can be determined by the chart shown in gure (6). Add
any length required to bypass roof obstructions.
The minimum vertical space required is equal to the length of the solar panel (8’, 10’ or 12’) plus
6” (150 mm) for the feed and return pipe runs above or below the array. Add a slope of 1 inch in
10 ft. (25mm per 3 meters) for the feed and return pipe runs to permit drainage.
Fig (6): Space Required for Solar Panel Arrays
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Installation Manual

Quantity of Panels “A”
in. m
3 12’-9” 3,89
4 17’-0” 5,18
5 21’-3” 6,5
6 25’-5” 7,77
7 29’-9” 9,06
8 34’-0” 10,36
9 38’-3” 11,65
10 42’-6” 12,95
11 46’-9” 14,24
12 51’-0” 15,54
8.4 Flow Rate through Array
The recommended ow rate through the array is 3 to 10 GPM (11 to 35 liters) per panel. A ow
rate of 5 GPM (18 liters) is recommended. The actual ow rate is not that shown on the pool
pump because of pressure losses in the system. The actual ow rate may be determined by using
an in-line ow meter or calculated the time it takes to ll a bucket of known capacity.
8.5 Control Module Location
Determine the location of the electronic control based on access to power, ease of cutting into
existing piping at the lter outlet, and piping to and from the array. (Refer to the control manu-
facturer’s instructions).
8.6 Pipe Size
Determine the length and size of the pipe required. Use only PVC pipe. Black ABS piping de-
grades when exposed to sunlight. Use pipe cleaner before gluing with PVC glue. If connecting to
ABS piping, use PVC glue, not yellow ABS glue. Allow several hours for glue to set before turning
on pump.
For runs of less than 80 ft (25 meters), either feed or return, use 1 ½”pipe. For runs of more than
80 ft. (25 meters) a 2”pipe is recommended. Pipe runs should be planned so that the panels and
piping drain when the system is not active.
8.7 Piping Arrangement (Figure 7)
a. Always pipe the array reverse-return. End-feed end-return systems are not ecient.
b. If possible, install the return pipe at the top of the array; this will eliminate the air in the
system.
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Installation Manual
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c. Feed at the lowest point in the system and connect the return line from all panels to the
highest point in the system.
d. All piping should be sloped continuously downward, towards the existing pump and lter.
If there are any low points or traps in the piping, drain plugs should be installed to ensure
complete drainage if the installation is an area subject to freezing conditions.
e. For multiple level, or split arrays, ensure that all return piping rises to a common high
point. Use abank kit (K15BKB) for multiple rows and a split kit (K15SPLB) for roof obstruc-
tions (see the part list of the pool systems in para 5).
Fig (7): Typical Panel and Piping Arrangements
8.8 Layout of the Solar Panel Array
a. Determine the exact location of the array, based on the required array conguration, the
existence of roof obstructions, proper feed and return pipe runs, shading of the panels and
any other specic factors that may aect the location of the array.
b. Utilizing a chalk line or string, make a horizontal line across as a reference for where the top
header of the panels will be located. Allow sucient room between the headers and the
roof line for pipe runs. Care must be taken to make the horizontal line truly horizontal. For
maximum protection against freezing, slope the entire array toward the feed pipe. The slope
should be 1” per 10’-0” (25 mm per 3 meters).
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c. Carefully check the roof, where the array is to be mounted, for any sharp projection (nails,
screws, etc.) that may damage the solar panels.
d. If the array is to be on multiple levels, or split roofs, repeat steps 1 through 4 above for each
portion of the array. Ensure that all return piping rises to a common high point.
8.9 Solar Panels
The SUNDWARE solar panels are designed to resist expansion and contraction due to temper-
ature variations. Even though the panels are made of resistant thermoplastic materials, care
should be taken when they are handled to avoid contact with sharp surfaces. When lifting the
panels onto the roof, take care not to damage them by dragging them over the edge of the roof.
8.10 Assemble the Solar Panel Array
The headers of adjacent panels are joined to each other by an EPDM hose (item # 9), with two
stainless steel gear clamps. Do not over tighten these clamps as it may cause the end of the
header to collapse. Care must be taken to ensure that the stainless steel gear clamps are placed
to match the groove in the header.
1. On the ground, prior to lift the panels on the roof, place an EPDM hose on one end of the
headers of each panel. Do not tighten the gear clamps, unless required to do so because of
wind or roof slope (see gures 8 and 9).
a. Place the second panel beside the rst so that the top headers are approximately 2 to 3”
(5 to 7 mm) apart.
b.Snap the top header of the second panel into the EPDM hose of the rst panel.
c. Rotate the bottom of the second panel toward the rst panel, and then snap it into
postion.
d.Tighten all gear clamps.
e. Repeat assembly procedures until array is complete.
F ig (8): Panel Assembly Fig (9): EPDM Panel Hose
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2. Roof obstructions (see gure 10) or split arrays (see gure 11) require that a PVC grooved
pipe to panel adaptor be inserted into the EPDM hoses. Each obstruction, or split, requires a
split kit (see the part list in para 5-Optional Items).
Fig (10): Split Kit Fig (11): Bank Kit
3. When an array has been assembled, it is ready to be secured to the roof. Adjust the array so
that the headers are sloped 1”per 10’-0” (25 mm per 3 meters) towards the feed line.
Fig (12): Split Kitor Last Panel Piping Details
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4. The feed line will be connected to the lowest point in the array and an end cap (item #6) will
be installed at the other end of the array in the bottom header.
5. The return line will be connected at the highest point in the array, opposite of the feed line,
and an end cap (item #6) will be place in the other end of the top header of the array. Con-
sult gure (7) for double bank arrays.
8.11 Mounting the Solar Panel Array
1. Starting at either end of the array, install a “U” steel support (item #11) over a top header
EPDM hose and anchor to the roof using two lag screws and washers (item #7). Make sure to
place a generous amount of caulking material on the roof at the point where the screws will
penetrate the surface (see gure 13).
2. Repeat this procedure across the array, securing a “U” steel support over each top header
EPDM hose. Only the top header of the array should be anchored in this manner.
Fig (13): Panel Mounting Details
3. For the installation of the rst mounting strap, locate a point on the roof approximately 12”
(300 mm) above thebottom header and 2” (50 mm) out from the edge panel. Tie a knot in
the end of the mounting strap (item #8), insert ina lag screw and washer, put caulking mate-
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rial and anchor to the roof. Extend the mounting strap across the array to theopposite end.
At this point, pull the strap tight, tie a knot, put caulking and anchor it to the roof using a lag
screw andwasher, 12” (300 mm) up and 2” (50 mm) out from the edge of the last panel. An-
chor mounting strap between eachpanels using lag screws and washers. Always use caulk-
ing when penetrating the roof.
4. Using the same procedure as in step 3, attach a second mounting strap at 18” (460 mm)
below the top header and athird one across the center of the array (see gure 14). For 12’-0”
panels, install across the array, a fourth mountingstrap equally spaced between the other
mounting straps.
Fig (14): Mounting Strap Arrangement
8.12 Flat Roofs
Flat roofs are more delicate to work on. Exercise extreme caution to prevent roof damage. Solar
panels can be mounted on at roofs if the length of the panels is sloped a minimum of 12” (300
mm) to ensure a good ow rate through the panels and to enable them to drain. A framework, il-
lustrated in gure (15) made of 2”x 4”and 2”x 6” boards, will support the solar panels along their
length. All wood products must be pressure treated, exterior grade. This support should extend
a minimum of 6” (150 mm) around the panel array to support the feed and return pipe runs.
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Quantity of Panels “A”
in. m
3 14’-9” 4,5
4 19’-0” 5,8
5 23’-3” 7,1
6 27’-6” 8,4
7 31’-9” 9,7
8 36’-0” 11,0
9 40’-3” 12,2
10 44’-6” 13,6
11 48’-9” 14,9
12 53’-0” 16,2
Fig(15): Flat Roof Rack
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Fig (16): Low Pitched Roof
Installation on low pitched roof with asphalt shingles, gravel or membrane, requires also a frame-
work of pressure treated wood (see gure 16). In both cases, the framework is attached to the
side of the house with a minimum of four steel cables (see gure 17). The waterproof membrane
of the roof is protected.
Fig (17): Roof Rack Attachment Details
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8.13 Ground Mounting Rack
This type of rack may be enclosed to serve as a shed for the pool lter. For dierent inclinations
see dimensions “B” and “C” in gure (18).
Degree “B” “C”
ft m ft m
25 10’-1” 3,0 5’-0” 1,5
30 9’-6” 2,9 5’-6” 1,7
35 9’-0” 2,7 6’-6” 2,0
40 8’-6” 2,6 7’-6” 2,3
45 8’-0” 2,4 8’-0” 2,4
Fig (18): Ground Mount Rack
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8.14 Plumbing the System
1. Feed and return connections to the array are made by inserting PVC grooved pipe to panel
adaptor into the panel EPDM hose and gluing the PVC pipe to the adaptor. Never attempt
to glue pipe directly to the solar panel header (see gure 12).
2. An end cap (item #6) must be plumbed into the array at the opposite end of the bottom
header to the feed line. If necessary, this end cap will totally drain the panels when the sys-
tem is winterized. More end caps can be used in the plumbing to facilitate drainage.
3. Isolating valves (optional), plumbed in the array feed and return lines, near the electronic
control, are recommended so that the array can be isolated if desired.
4. With a pool ltration system far from the house, where the solar panels are installed, feed
and return lines are buried (see gure 19). Flexible corlon polyethylene piping is suggested
because it is more resistant to freezing. Rigid PVC pipe may freeze and break. Install drain
plugs at the both ends of the underground pipes using the underground kit K15UNG (see
para 5 –Parts List).
Fig (19): Underground Kit
5. Insulation is not needed since the pool water temperature and ambient air temperature are
almost the same. Winter conditions of snow and ice make it imperative that the system be
checked once a year by a qualied installer: solar panel mounting straps, sensor wire, caulk-
ing, piping fastening and pipe drainage.
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8.15 Plumbing Connections
1. Make a mock up with pipe ttings and the manual or automatic controller, to determine
the piping requirements. Follow the instructions supplied by the manufacturer of the
controller.
2. After determining size requirements, cut out the appropriate amount of existing piping.
3. Convert to PVC pipe with threaded adaptors. Always use Teon tape on threaded joints to
avoid leakage.
4. Feed and return piping should go around overhanging eaves to minimize risks of leaks.
9. Installation Procedure
The following procedure assumes a shingle roof:
Step (1): Establish a horizontal chalk line across the roof for the location of the top of the
system.
This line must have 3/4” clearance above and below it for mounting the Header Clip on a
flat surface. For tile roofs, the line should be approximately 2”above the bottom of the tile.
Note: For seasonal climates, this line must have a ¼” per foot slope towards the feed line
to allow for drainage and winterization. Then drop a vertical line (90° to the horizontal
line) at the left or right end of the installation to locate the first panel. Allow a minimum of
3” on all sides of the panel row for piping. Inspect the roof for any sharp projections that
may damage the panels.
Step (2): Lay out the system before securing any panels. Begin installing the panels on the
left working right towards the opposite end. The panels can be installed with either side
up, and should be flipped after five years to lengthen their life.
Step (3): Lay the top header approximately 1¼” below the horizontal chalk line. Using the
parts from the Panel Kit, install a 3” Rubber Coupling on the top right and bottom right
header outlet. Slide a Hose Clamp over each Rubber Coupling and position it over the
groove in the header. Rotate the head of each clamp facing up for easy access, shown in
Fig (20). Then tighten until snug.
Step (4): Slide another Hose Clamp over the top and bottom Rubber Coupling. Position
the next panel to the right of the first panel, and insert the header outlet into the top and
bottom Rubber Coupling of the first panel. Position each Hose Clamp over the groove of
the second panel; facing up for easy access. Then tighten until snug. The top and bottom
should resemble Fig (21) when finished. If the roof is not too steep for the panels to slide,
you may continue connecting panels following Step 3 then Step 4; otherwise move to
Step 5
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