Swim Joy 2-1100-008 User manual

Before attempting installation, read these instructions and
acquaint yourself with the component names. Great care has
been taken to make this an easy-to-follow procedure.
A little time spent understanding the system and its parts
will assure a successful, trouble-free installation.
CAUTION: SAFETY COMES FIRST
When working on or around your roof or pool, please take care
to avoid hazards such as electrical wires and loose shingles.
R.2021.1
RESIDENTIAL INSTALLATION MANUAL
SWIM JOY SOLAR POOL HEATER

Swim Joy panels are manufactured utilizing cutting
edge technology and the most advanced
production techniques. A Swim Joy solar system will
provide years of worry-free performance as it captures
safe, reliable heat from the sun year after year.
This manual will give you a great deal of valuable
information. Take time and read through this manual. It
will guide you through the most efficient way to correctly
install an Swim Joy solar system. By following this step-
by-step guide, your system will meet the installation
standards recommended by the factory.
While the manual explains how to install Swim Joy solar
panels properly in typical situations, it cannot address
all the unique or individual circumstances possible. If
you have any installation questions, contact your Swim
Joy Representative for assistance. As the installing
contractor, you are responsible for exercising good
judgment when installing Swim Joy systems to
protect the long term integrity of the panels as well
as the mounting surfaces.
1. Introduction/Table of Contents
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER INTRODUCTION/TABLE OF CONTENTS - 1
1. Introduction
2.Getting Started
3. Things To Remeber
4. Installation Kits & Components
5. Installation Materials & Tooling
6. Solar Panel Layouts & Hydraulics
7. Connecting the Solar Panels Together
8. Mounting the Solar Panels
9. Mounting the Solar Panels On A Flat Roof or
Ground Rack
10.Assembly of Row Spacer Kits
11.Connecting the Solar Panels to the Feed &
Return Lines
12.Running the Feed & Return Lines From Roof to
Ground Level
13.Connecting the Feed & Return Lines to the
Filtration System
14.Pressure Testing the System
15.Operation & Check-Out Procedures
16.Troubleshooting
17.Repair Procedures

2. Getting Started
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER GETTING STARTED - 2
1.
2.
3.
4.
5.
6.
7.
Caution - SAFETY COMES FIRST!
There is no substitute for safety. Always exercise extreme caution, care, and good judgment when working on or
around a roof or pool area.
BEFORE YOU START YOUR INSTALLATION, HERE ARE A FEW IMPORTANT TIPS:
Check with your local building department to determine permitting and code requirements in your area.
While this manual explains how to install Swim Joy solar panels properly in typical situations, it cannot possibly
address all the unique or individual circumstances possible. If you have any installation questions, contact your
Swim Joy representative for assistance.
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 the 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. Be sure that
the layout of the panels will allow the panels to drain when the pool pump shuts off.
Familiarize yourself with all of the Swim Joy components and plumbing materials that you will need to complete
the installation.
Don’t take shortcuts. Whenever possible, panels should be installed so they are accessible without being walked
on. Walking on the panels should only take place when absolutely necessary.
Depending upon your specific job, you will need various plumbing items and materials. Be sure to use quality
products that will withstand direct sunlight year after year.
• Please take care to avoid hazards such as overhead electrical wires or loose shingles.
• 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.
PVC PIPE - Use PVC SCHEDULE 40 pressure rated pipe. Do not use ABS or a lower standard substitute.
PVC FITTINGS - Use PVC SCHEDULE 40 pressure rated fitting to match your PVC pipe.
DO NOT USE - “plumber’s” fittings or DWV fittings (drain, waste, vent).
PVC CLEANER AND CEMENT - It is important to both CLEAN and CEMENT each PVC joint. When gluing CPVC fittings
to PVC pipe, such as the (2-1810-005) pipe connector, it is necessary to use a good quality multi-purpose cement.
NOTE: As the installer, you are responsible for exercising good judgment when installing Swim Joy systems
to protect the long term integrity of the panels as well as the mounting surfaces.

3. Things to Remember
THINGS TO REMEMBER - 3
NO TWO INSTALLATIONS ARE EXACTLY ALIKE BUT
THERE ARE SOME GENERAL BITS OF TECHNICAL
INFORMATION THAT YOU WILL FIND HELPFUL IN
THE FIELD.
ROOF ORIENTATION - Ideally, panels should be
located on a south facing or flat roof or on an
elevated ground mounted rack facing south. The next
best orientation is west and finally east. Panels should
never be installed facing north in the Northern
hemisphere.
PANEL CONFIGURATIONS - There are many ways to
configure a solar array. The most common and
preferred is in a continuous row. The recommended
limit to the number of panels that can be installed this
way to achieve even flow throughout the array is (12)
4'x7.5' panels, (10) 4'x10.5panels , or (8) 4'x12.5' panels.
This maximum guideline can be exceeded if there is a
high flow or substantial back pressure on the system
which will force adequate flow through every panel.
When you have more than the maximum, you should
either use the double row layout or the single row split
feed layout. Of course, the double row can also be used
for smaller installations when space is a problem. (Fig.
10.2, page 10).
If you have to split up an array due to a skylight or
change in roof level or direction, the layout will be
similar to single row split feed layout.
PUMP HORSEPOWER - The horsepower of your
swimming pool filtration pump must be adequate to
supply the solar system with enough water to provide
the recommended flow rate necessary for the panels
being installed. The recommended rates are:
Generally, a 1-horsepower pump is sufficient for a
standard pool solar system unless there is an unusually
long pipe run, a high roof or a large number of
panels. If you are not sure what your pump flow rate is,
consult your Swim Joy representative for the
pump’s flow characteristics.
PLUMBING - It is important that you use the proper
size PVC pipe for the size of the solar array. Under
sizing the pipe will produce too much restriction to the
water flow and unnecessarily reduce the flow rate to
the panels. Use the following as a guide:
Plumbing runs should be as short as possible and the
“hot return” pipe should have the shortest run to
reduce the potential heat loss in the pipe. Horizontal
pipes should be supported with a pipe clamp at least
every 4 feet to prevent sagging. The pipe clamp used
on pipe runs across a roof should be ½” larger than the
pipe diameter to allow for expansion and contraction,
unless you are using our glass-reinforced PP pipe
clamps (see page 8) that expand and contract with the
pipe. Pipe clamps should be used on vertical or
horizontal runs on the side of a building and should be
the same size as the pipe diameter to prevent
movement.
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER

3. Things to Remember, - Cont.
AUTOMATIC DRAIN DOWN - Both the solar panels and the PVC pipe should be installed so the water will drain out of them when
the pump shuts off. A non-positive or solar 3-port valve is required for automatic drainage. This is especially important in
areas of the country where harsh winter conditions cause freezing conditions; however, the freezing point for solar panels starts at 40
degrees, so freeze damage can occur in virtually any area of the United States.
The Swim Joy solar pool panels are warranted against internal freezing when installed to allow for drain down. If, as a result of a
unique roof design or adverse pool equipment locations (as demonstrated in figure 4.1 below), it is not possible to achieve complete
automatic drain down, manual drain down valves should be installed in appropriate places in the plumbing or at the end of the
bottom (feed) header.
Instead of installing an end cap (2-1810-013) at the end of the header, you would install a manual drain down bib attachment set
(1-5115-021AS).
These valves should be opened when shutting down the system for the winter months or when freezing conditions are possible. Your
Swim Joy representative can assist you with the parts necessary for manual drain down installations.
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER THINGS TO REMEMBER CONT - 4
Fig 4.1

This page details all of the Swim Joy installation kits included with each DIY System Kit that are required to install a Swim Joy
solar pool heating system in one single row as detailed in figure 10.1 on page #10. These DIY System Kits are designed as a
"base" starting point. Given the endless variables to each installation it is impossible to include all of the materials and
components necessary to complete each and every installation. Additional components may be required depending on your
specific installation and layout requirements. Page #6 details optional installation kits offered separately that may be
required depending on the layout, installation, operation and maintenance requirements of your specific installation.
2-1145-001: PANEL INSTALLATION KIT
One of these kits is required for each panel. Your DIY System Kit will include one panel installation kit for each solar panel. It
contains the parts necessary to connect the panels together and secure them to the mounting surface. Each installation kit
contains: (2) 2-1160-001 Mounting Pad Top, (2) 2-1160-002 Mounting Pad Bottom and (2) 2-1810-004 Panel Clamp Assembly.
2-3045-001: ROW INSTALLATION KIT
One of these kits is required for each row of panels. Your DIY System Kit will include one row installation kit. It contains the parts
necessary to connect the feed and return lines to one row of panels. If your specific layout requires more than one row of panels,
you will need one additional row installation kit for each additional row of panels. The row installation kit contains: (2) 2-1810-004
Panel Clamp Assembly, (2) 2-1810-013 End Cap and (2) 2-1810-005 Pipe Connector CPVC.
2-1410-023A: VACUUM RELIEF VALVE ATTACHMENT SET
One of these kits is required for each system. Your DIY System Kit will include one vacuum relief valve attachment set. It contains the
parts necessary to allow air into your system for proper gravity drainage. The attachment set contains: (1) 2-1810-029 Vacuum
Relief Valve, (1) 2-2015-082 Reducer Bushing and (1) 401-020BC Schedule 40 PVC "T" Fitting, 2", White.
2-3020-022: PRESSURE TESTING KIT
This kit gives you the components required to pressure test the system once installation is complete. The pressure testing kit comes
as one "T" assembly featuring a ball valve and pressure gauge. Attaches to 3/4" FPT reducer bushing (located in vacuum relief valve
location of the 2-1410-023A attachment set).
4. Installation Kits & Components
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER INSTALLATION KITS & COMPONENTS - 5

INSTALLATION KITS & COMPONENTS CONT - 6
4. Installation Kits & Components, - Cont.
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER
The following is a description of optional installation and service kits that are offered separately. These items may be
necessary depending on the layout, installation, operation and maintenance requirements of your specific installation.
2-3045-003: ROW SPACER KIT
One of these kits is required if you need to space around a roof obstruction larger than 6" or an obstruction that is too close to the
header , such as a skylight, chimney, vent tube, etc. It can also be used to connect different rows of panels into one row that
are on different roof levels or on different roof pitches that are facing different directions. It contains the parts
necessary to connect the rows of panels utilizing PVC pipe between them. The installation process for the row spacer kit
is detailed on page #23. Each row spacer kit contains: (4) 2-1810-005 Pipe Connector and (2) 2-1810-004 Panel Clamp
Assembly.
2-3045-001: ROW INSTALLATION KIT
One of these kits is required for each row of panels. Your DIY System Kit will include one row installation kit. It contains the parts
necessary to connect the feed and return lines to one row of panels. If your specific layout requires more than one row of panels,
you will need to purchase an additional row installation kit for each additional row of panels. The row installation kit contains: (2)
2-1810-004 Panel Clamp Assembly, (2) 2-1810-003 End Cap and (2) 2-1810-005 Pipe Connector CPVC.
2-3020-029: REPAIR TOOL KIT
In the event a panel riser tube is damaged, this kit contains everything needed to make a repair to a riser tube. The repair kit
contains: (1) 2-1810-007 Plug Insertion Tool, (1) 2-1910-008 Chisel Cutting Tool and (16) 2-1120-001 Repair Plugs.
1-5115-021AS: MANUAL DRAIN DOWN BIB ATTACHMENT SET
For installations that will not automatically drain due to installation location or plumbing limitations, this set will allow you to
manually drain water from your panels directly at the header. This set contains: (1) 2-1810-005 Pipe Connector, (1) 429-020B PVC
Coupling, (1) 2-2015-082 Reducer Bushing and (1) Drain Bib, Brass.
2-1410-023H: VACUUM RELIEF VALVE ATTACHMENT SET, HEADER MOUNT
For installations below pool grade or installations that will not automatically drain, a header mount vacuum relief valve is
recommended to allow air into the panels when the feed and return lines are isolated with diverter or ball valves. This set should be
combined with the manual drain down bib attachment set (#1-5115-021AS) to allow all of the water to drain from the panels. This
set contains: (1) 2-1810-005 Pipe Connector, (1) 406-020B PVC Elbow, 90 Degree, Black, (1) 2-2015-082 Reducer Bushing and (1)
2-1810-029 Vacuum Relief Valve, 3/4" MPT.
4. Installation Kits & Components, - Cont.

4. Installation Kits & Components, - Cont.
PANEL INSTALLATION KIT
Part #2-1145-001
ROW INSTALLATION KIT
Part #2-3045-001
VACUUM RELIEF VALVE ATTACHMENT SET
Part #2-1410-023A
ROW SPACER KIT
Part #2-3045-003
PRESSURE TESTING KIT
Part #2-3020-022
VACUUM RELIEF VALVE HEADER
ATTACHMENT SET Part #2-1410-023H
MANUAL DRAIN DOWN BIB ATTACHMENT
SET Part #1-5115-021AS
SOLAR PANEL REPAIR KIT
Part #2-3020-029
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER INSTALLATION KITS & COMPONENTS CONT - 7

MOUNTING PAD, TOP HEADER
Part #2-1160-001
MOUNTING PAD, BOTTOM
HEADER Part #2-1160-002
CPVC PIPE CONNECTOR
Part #2-1810-005
END CAP
Part #2-1810-013
PANEL CLAMP BOTTOM
Part #2-1810-015
PANEL CLAMP TOP
Part #2-1810-020
PANEL CLAMP GASKET
Part #2-1810-017
PANEL CLAMP LATCH
Part #2-1810-018
VACUUM RELIEF VALVE
Part #2-1810-029
REPAIR PLUGS
Part #2-1120-001
PVC PIPE SUPPORT BRACKET
BLACK, 2" Part #30272-2
(White & 1.5" Also Available)
EXTRA WIDE TOP HEADER
BRACKET Part #2-1160-003
INSTALLATION KITS & COMPONENTS CONT. - 8
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER
4. Installation Kits & Components, - Cont.

5. Installation Materials & Tooling
INSTALLATION MATERIALS & TOOLING - 9
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER
Our DIY System Kits are designed as a "base" starting point. Given the endless variables to each installation it is impossible to include all
the materials and components required to complete the installation. Each installation is unique and will require additional components
and materials to complete the installation based on panel layout, piping, roof material, etc. Below is a list of components, materials and
tooling that may be required depending on your specific installation.
MATERIALS
• Schedule 40 PVC Pipe • Schedule 40 PVC Fittings
• 3-Port Valve • 2-Port Valve
• Check Valve • Lag Screws
• Silicone Spray • Pipe Supports
• Zip Ties • Electrical Wire Nuts
• 12ga-14ga Electrical Wire With Ground • Electrical Conduit
• PVC Cement (Primer & Medium)
• Ball Valve
• High Quality Sealant
• Flow Meter
• 18ga-22ga Sensor Wire
• Teflon Tape
TOOLING
• Power Drill With Corresponding Bits & Sockets • Basic Hand Tools
• Channel Lock Pliers • Caulking Gun
• Pipe Cutter, Hacksaw Or Reciprocating Saw To Cut PVC Pipe • Ladder
NOTE: While this manual explains how to install Swim Joy solar panels properly in typical situations, it cannot address all the unique
or individual circumstances possible. It is the installers responsibility to exercise good judgment and follow proper installation
procedures to protect the long-term integrity of the panels as well as the mounting surfaces.

SOLAR PANEL LAYOUTS & HYDRAULICS - 10
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER
6. Solar Panel Layouts & Hydraulics
The following 4 layout and plumbing diagrams are the most common solar panel installations.
Fig. 10.1 - SINGLE ROW
Fig. 10.2 - DOUBLE ROW
Fig. 10.4 - SINGLE ROW SPLIT FEED
Fig. 10.3 - SINGLE ROW SERIES FEED

SOLAR PANEL LAYOUTS & HYDRAULICS CONT - 11
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER
6. Solar Panel Layouts & Hydraulics. - Cont.
Figure 11.1 below details the installation locations of the mounting hardware included in each DIY System Kit. This is an example of a
common installation. Mounting locations may differ due to system location, roof truss location, roof material type, etc. For commercial
installations please contact a Swim Joy representative for system design assistance.
Top Mounting Pad Bottom Mounting Pad PVC Pipe Support Bracket
Panel Clamp Assembly End Cap CPVC Pipe Connector
NOTE: On soft roof surfaces or lesser quality asphalt shingle materials an EPDM or aluminum pad underneath the panel clamp
assembly may be necessary to eliminate possible roof wear.
NOTE: The spacer bars that hold the individual riser tubes together should be facing down onto the mounting surface
lifting the panel up off of the mounting surface.
Fig. 11.1

These maximums can be exceed if there is high flow or substantial back pressure on the system, which will force
adequate flow through every panel. When you have more than the maximums, you should either use the double row
layout detailed in Fig. 10.2 or the single row split feed layout detailed in Fig. 10.3 on page# 10. Of course, the double
row can also be used for smaller installations when space is a problem.
Whenever possible, the 2-1100-050 (4'x12.5') panel should be used. This will reduce the total cost of the system,
reduce installation time and materials, reduce the width of solar array, reduce the number of roof penetrations and
produce a more attractive installation.
However, unique roof designs may require a combination of different size panels to best cover the roof area.
PANEL CONFIGURATIONS - There are many ways to configure a solar array. The most common and preferred is in
one continuous row as shown in Fig. 10.1 on page #10. However, there are recommended limits to the number of
panels that can be installed this way to achieve balanced flow throughout the array. The maximum number of
panels per row are:
6. Solar Panel Layouts & Hydraulics. - Cont.
ROOF ORIENTATION - Ideally, panels should be located on a south-facing or flat roof on an elevated ground mounted rack
facing south. The next best orientation is west and finally east. A panel should never be installed on a north roof without a
reverse rack in the Northern hemisphere.
CHOOSING THE RIGHT SIZE PANEL - The roof space available to you will determine which model panel to use. Since Swim Joy
manufactures panels in ten different sizes, you have great flexibility in what you can design. The ten panels sizes are:
SOLAR PANEL LAYOUTS & HYDRAULICS - CONT - 12
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER

PUMP HORSEPOWER - The horsepower of your swimming pool filtration pump must be adequate to supply the
solar system with enough water to provide the recommended flow rate necessary for the panels being installed. These
recommended rates in gallons per minute (GPM) are (0.1gal/ft²).
For example: If you are installing (10) 2-1100-040 (4'x10.5'), which is 420 sq ft of panels, utilizing the single row or
double row layout (excluding series feed), your pump must be able to deliver 42 GPM to the solar array. The existing
pool recirculation pump is typically adequate for recirculating the water through the solar system. Generally, a 1-
horsepower pump is sufficient for a standard pool solar system unless there is an unusually long pipe run, a two-story
roof, or a large number of panels. If you are not sure what your pump flow rate is, consult your Swim Joy
representative or pump manufacturer for the pump’s flow characteristics.
PLUMBING - It is important that you use the proper size PVC pipe for the size of the solar array. Under sizing the pipe
will produce too much restriction to the water flow and unnecessarily reduce the flow rate to the panels. Use the
following as a guide:
For larger flow rates, consult your Swim Joy representative for the proper pipe size or alternative series plumbing
techniques, which will reduce the necessary flow rates on larger systems.
Plumbing runs should be as short as possible and the “hot return” pipe should have the shortest run to reduce potential
heat loss in this pipe. Pipes should be supported with pipe clamps or “G” clamps at least every 4 feet to prevent sagging.
(Check with plumbing code in local jurisdiction. The pipe clamp used on pipe returns across a roof should be ½” larger
than the pipe diameter to allow for expansion and contraction. The pipe clamp used a on vertical or horizontal runs
on the same side of the building should be the same size as the pipe diameter to prevent vibration and to assure
a professional looking installation. We highly recommend our Glass-Reinforced PP Pipe Support Brackets as they fit
snugly around the PVC pipe, expand and contract with the pipe and also utilize a flashing base to better seal the roof
penetration. We offer these pipe clamps in 2" Black (#30272-2), 2" White (#30284-2), 1.5" Black (#30272-1) and 1.5"
White (#30284-1).
Since 90-degree elbow fittings produce a high restriction to flow, you will want to use as few as possible; keep this in
mind when planning your plumbing runs. Their use cannot be avoided, but with careful forethought, you will use the
least number possible. The use of (2) 45-degree fittings will eliminate a 90 and reduce flow restriction.
6. Solar Panel Layouts & Hydraulics. - Cont.
SOLAR PANEL LAYOUTS & HYDRAULICS - CONT - 13
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER

BALANCED FLOW - When you have to split a solar system as in Fig. 10.2 or Fig. 10.3, page #10, it is critical that the
shown plumbing runs be followed to assure equal water flow through both rows of panels. Since water will follow the
path of least resistance, if one plumbing run is shorter than the other, more water will flow through it than through the
other one. Keep this in mind if you design a panel layout different than the examples. Your Swim Joy representative can
also assist with this and explain the use of “balancing valves” on larger systems.
If you are installing the solar panels on a flat roof or flat ground rack, the top (return) header of the panel should be at
least 3” higher than the bottom (feed) header to assure equal flow through all of the tubes of all the panels. To achieve
even distribution of water throughout the row of panels, proper flow rates and a little back pressure should be present.
AUTOMATIC DRAIN DOWN - The panels and the PVC pipe should be installed so the water will drain out of them
when the pool pump shuts off. This is especially important in areas of the country where freezing conditions occur. (The
Swim Joy solar pool panels are warranted against internal freezing when installed to allow for drain down.) To allow
for the water to drain, a vacuum breaker (2-1810-029) is installed on the solar feed line above the non-positive three-
way valve as shown in (Fig. 26.1, page #26). (Non-positive means that the valve allows for water to drain back through
the valve even while in the off position. If you have a 3-way valve that is not non-positive, you can make it so by drilling
an 1/8” hole in the diverter). If, as a result, of a unique roof design or adverse pool equipment location, it is not possible
to achieve complete automatic drain down, manual drain down valves should be installed in appropriate places in the
plumbing or at the end of the bottom (feed) header.
6. Solar Panel Layouts & Hydraulics. - Cont.
SOLAR PANEL LAYOUTS & HYDRAULICS - CONT - 14
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER
Instead of installing and end cap (2-1810-013) at the
end of the header, you would install a Manual Drain
Down Bib Attachment Set (#1-5115-021AS). A top
header mounted vacuum relief valve (#2-1410-023H)
would be ideal to allow air into the panel array as
well. Fig. 14.1to the right is an example of an
installation that will not automatically drain and
details the additional components required to
manually drain the solar panels. These valves should
be opened when shutting down the system for the
winter months or when freezing conditions are
possible. Your Swim Joy representative can assist you
with the parts necessary for the manual drain down
installations.
NOTE: Solar panels can be freeze damaged if
temperatures reach 40 degrees Fahrenheit, so freeze
damage can occur in virtually any weather climate. It
is extremely important to take the necessary steps to
ensure your system will automatically gravity drain, is
automated with a control system that features freeze
protection or is installed with the proper components
to manually drain the system.

7. Connecting the Solar Panels Together
Later on in this installation manual you will be instructed to connect the panels together using the panel clamp
assemblies. When connecting panels together, follow the directions outlined below:
Place two panels next to each other
and ensure all required components,
tools and sealant are ready to
complete assembly.
Clean the grooves of both headers.
Apply proper sealant to the gasket
and insert one gasket into either
header.
Join both headers together ensuring
the gasket is properly located in both
header grooves and fully seated.
Only one gasket is used for each
connection.
Place the bottom clamp underneath
where both of the headers meet.
You can apply some pressure to the
top of the headers to start
compressing the gasket.
Place the top clamp interlocking it
with the bottom clamp swinging
the top clamp around the header
and aligning the angled latch
portion of both clamps.
Compress the clamp assembly with
channel lock pliers, which requires a
good amount of force, and slide the
latch onto the clamp.
CONNECTING THE SOLAR PANELS TOGETHER - 15
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER

7. Connecting the Solar Panels Together. - Cont.
Use channel lock pliers to fully seat the
latch onto the panel clamp assembly.
Insert the locking clip through the latch
and into the panel clamp assembly
locking the latch in place.
Panel clamp assembly connection is now
complete. The panel clamp assemblies are
used to connect panels together at both
top and bottom headers, attach end caps
and attach pipe connectors.
NOTE: On soft roof surfaces or lesser quality asphalt shingle an EPDM or aluminum pad underneath the panel clamp assembly
may be necessary to eliminate possible roof wear.
Complete Panel Clamp Assembly
Kit Part #2-1810-004
NOTE: The spacer bars that hold the individual riser tubes together should be facing down onto the mounting surface
lifting the panel up off of the surface.
CONNECTING THE SOLAR PANELS TOGETHER - CONT. - 16
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER

One of the top benefits of the Swim Joy installation method is its versatility. The mounting pad’s flexibility allows
installation of the Swim Joy panels on virtually any roof or rack surface regardless of pitch. To properly install
panels utilizing the mounting pads follow these few steps:
2.
3.
Snap a chalk line across the roof where you want the top edge of the panel header to be. This chalk line should slope
upward towards where the return line will be located, to allow for proper drainage. The return line corner of the panels
should be the top corner closest to the pool pump so that once the water is heated, it will be returning to the
pool as quickly as possible. Be sure to allow 2” of clearance above this chalk line for the mounting pads.
Lay the first two panels so that the top edge of the top header is located at the chalk line. Referencing Fig. 17.1, slide a
top mounting pad onto the 1st rail of the top header of the first panel (Panel "A"), and another top mounting pad onto
the 3rd mounting rail of the same panel (Panel "A"). The mounting pad position of Panel "A" will continue for the rest of
the row, until you get to the last panel (Panel "B"). For the last panel in the row (Panel "B), place a top mounting pad at
the 1st rail, and the second mounting pad on the 4th rail, so that each end of the row is secured at the very outside
edge.
After positioning the mounting pads in the proper location on the first panel (Panel "A), apply an ample amount of roof
sealant to both the lag screw and to the roof for the 1st mounting pad connection. Position the 1st mounting pad on
the roof and secure to the roof. The lag screws should be securely fastened, but not over-tightened. Don't
secure the second mounting pad on the 3rd rail of the first panel yet. Assembling the panels in this order
will make connecting the headers together with the panel clamp assemblies much easier. Next, connect the
top headers of the first and second panels together using the (PPC) plastic panel clamp assembly by
following the procedures described on page #15 titled "Connecting the Solar Panels Together". Once the top
header of the first and second panel are connected with the panel clamp assembly, you can secure the
second mounting pad located on the 3rd rail of the first panel. Repeat these steps to secure all panels to
the mounting surface.
The last panel (reference Panel "B" in Fig. 17.1) should be secured with a top mounting pad on the 1st rail and the
second mounting pad on the 4th rail. This secures the row at both outside edges.
8. Mounting the Solar Panels
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER MOUNTING THE SOLAR PANELS - 17
4.
1.
Fig. 17.1
NOTE: This is the recommended mounting pad location for common installations. However, it is acceptable to
position the mounting pads on different rails to align with roof trusses, barrel tile roof ridges, etc.

8. Mounting the Solar Panels. - Cont.
MOUNTING THE SOLAR PANELS - CONT. - 18
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER
Once all of the top headers are connected with the panel clamp assemblies and all of the top mounting pads are
secured to the mounting surface, you can repeat the same mounting pad and panel clamp assembly installation steps
for the bottom headers and mounting pads.
5.
NOTE: For tile roofs, anchor screw sets can be used for clay tile and concrete lag screws can be used for concrete tiles
to attach the mounting pads to the tile. Using these style screws for tile roofs avoids the need to penetrate the roof
membrane or substrate in cases where the roof tiles are properly anchored to the roof. On all types of roofs be sure to
seal each penetration with the proper sealant.
NOTE: On soft roof surfaces or lesser quality asphalt shingle an EPDM or aluminum pad underneath the panel clamp
assembly may be necessary to eliminate possible roof wear.
The bottom mounting pads feature a unique design that both secures the bottom header to the mounting surface while
still allowing the panel to thermally expand and contract.
Notice the graphic marks (Fig. 18.1) on the slider portion of the bracket. These marks are here to assist you in determining
how to position the mount during installation. Each symbol refers to a possible weather condition: “snowflake” for cold
and “heat waves” for hot. When it’s hot outside, the panel is longer and when it’s cold, the panel is shorter.
While installing the bottom mounting pads, you should consider the current ambient temperature and position the
slider over the track (and grid) so that it is closer to the icon that best defines the weather. This will allow enough room for
the system to expand and contract as needed. If you are unsure, install the mount at the 4th line as referenced in Fig. 18.2.
This location gives the panel equal room to both expand and contract.
Fig. 18.1
Fig. 18.2
Fig. 18.3

FLAT ROOF: If you have chosen a flat roof to mount the solar panels, it is recommended not to penetrate the surface
with a lag bolt. As the installer, you are responsible for making sure that the installation will not damage the roof
surface. Due to the variety of flat roof materials, please contact a Sim Joy representative for mounting advice to your
specific roof type and installation location.
GROUND RACK: When solar panels are installed on a rack, a substrate should be mounted on the rack prior to mounting
the panels. This reduces heat loss from wind, improves solar heating performance and reduces wind lift stress on the
panels and mounting hardware. Fig. 19.1 below is an example of a rack constructed of galvanized steel framing
stud material. Fig 19.2 shows the substrate, which is galvanized steel roofing panels flipped upside down to create
a flat mounting surface. All of these materials are common and available from almost any hardware store or material
supplier. We have more detailed rack information and can assist with rack design and dimensions to fit your needs,
so please contact a Swim Joy representative for further assistance.
INSTALLATION MANUAL - SWIM JOY SOLAR POOL HEATER MOUNTING THE SOLAR PANELS ON A
FLAT ROOF OR GROUND RACK - 19
Fig. 19.1
Fig. 19.2
9. Mounting the Solar Panels On A Flat Roof or
Ground Rack