UMA Solar Heliocol Series User manual

RESIDENTIAL
INSTALLATION MANUAL
HELIOCOL®SOLAR POOL HEATER
1405 | Rev. 05
HC-INSTALL | 1405
©2014 UMA Solar
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. If you have any product or installation questions,
contact your Heliocol representative.

Heliocol solar panels are manufactured utilizing state-
of-the-art solar technology and the most advanced
production techniques. Heliocol collectors are sleek and
simple, yet the patented over-molded design makes
Heliocol durable enough to last a lifetime. However, a
professional installation is very important to the overall
success of a system. Installed properly, a Heliocol System
will be virtually maintenance free as it captures free,
abundant, and reliable heat from the sun year after year.
Whether you are a seasoned contractor or a homeowner
installing your own system, this manual will give you a
great deal of valuable information.
Take time to read through this manual. It will guide
you through the most efficient way to correctly install
a Heliocol solar system. By following this step-by-step
guide, your system will meet the installation standards
recommended by the factory (see disclaimer on front
page. In addition, because we’ve included techniques
and tips gathered from experienced Heliocol contractors
throughout the country, using this installation will save
you time and effort.
11. Introduction.
22. Getting Started.
33. Things to Remember.
54. Installation Kits & Components.
65. Parts Breakdown.
76. Solar Panel Layout & Hydraulics.
12 7. Connecting the Solar Panels Together.
14 8. Mounting the Solar Panels
Using Gator Clamps.
17 9. Mounting the Solar Panels On A Flat Roof.
18 10. Assembly of Row Spacer Kits.
19 11. Connecting the Solar Panels to
the Feed & Return Lines.
20 12. Running the Feed & Return Lines
from Roof to Ground Level.
22 13. Connecting the Feed & Return Lines
to the Filtration System.
1. Introduction/Table of Contents.
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER INTRODUCTION/TABLE OF CONTENTS -1
25 14. Pressure Testing the Heliocol System.
26 15. Operation & Check-out Procedures.
28 16. Troubleshooting.
32 17. Repair Procedure.
©2014 UMA Solar

2. Getting Started.
INSTALLATION MANUAL HELIOCOL®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 Heliocol solar collectors properly in typical situations, it cannot possibly
address all of the unique or individual circumstances possible. If you have any installation questions, contact your
Heliocol 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 collectors will allow the collectors to drain when the pool pump shuts off.
Familiarize yourself with all of the Heliocol 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 collectors 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.
©2014 UMA Solar
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 fittings 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 2-1410-005 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 Heliocol systems to
protect the long term integrity of the collectors 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, collectors 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. Collectors
should never be installed facing north in the Northern
hemisphere.
COLLECTOR 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 collectors that can be installed this way
to achieve even flow throughout the array is (12) HC-30’s,
(10)HC-40’s, or (8) HC-50’s.
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 collector.
When you have more than the maximum, you should use
either 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. 6.2,
page 7).
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 collectors
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
collectors. If you are not sure what your pump flow rate
is, consult your Heliocol 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 collectors.
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. 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.
FLOW RATE MINIMUM PIPE SIZE
0 to 30 GPM 1½”
31 to 50 GPM 2”
51 to 70 GPM 2½”
PANEL RECOMMEND FLOW RATE
HC-30 3-4 gallons per minute
HC-40 5-6 gallons per minute
HC-50 6-7 gallons per minute
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

3. Things to Remember. - Cont.
THINGS TO REMEMBER. -4
AUTOMATIC DRAIN DOWN - The collectors and the PVC
pipe should be installed so the water will drain out of
them when the pool shuts off. This is especially important
in areas of the country where freezing conditions occur.
The Heliocol solar pool collectors 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, 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 (2-1410-013) at the
end of the header, you would place a (2-1410-005) type
connector (2-1410-004) 1½” x 1½” THD PVC reducer
bushing along with a ½” boiler drain (1-5115-017)].
These valves should be opened when shutting down
the system for the winter months or when freezing
conditions are possible. Your Heliocol representative
can assist you with the parts necessary for manual drain
down installations.
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

One of these kits is required for each row or bank of collectors. It contains the parts necessary to connect the collectors to the feed and
return lines.
This kit gives you the components you need to pressure test the system once installation is complete.
In the event a collector is damaged, this kit contains everything needed to make a repair to a riser tube.
2-1045-001: COLLECTOR KIT
2-3045-003: ROW SPACER KIT
2-3045-001: SYSTEM KIT
2-3020-022: PRESSURE TESTING KIT
2-3020-025: REPAIR TOOL KIT
INSTALLATION KITS & COMPONENTS -5
One of these kits is required for each collector it contains: (1) 2-1410-004 plastic panel clamp, and (2) 2-1060-001, and (2) 2-1060-002.
One of these kits is required if you need to bypass a vent pipe or obstacle larger than 6”. It is also used to connect collectors into one row
that are on dierent roof levels or that are facing dierent directions. It contains the part necessary to connect the collectors to the PVC
pipe between them.
4. Installation Kits & Components.
The following is a description of the installation kits that are required for a complete Heliocol installation. The (2-3045-
001) system kit and (2-1045-001) collector kits are always required while the (2-3045-003) row spacer kit is only required
for certain installations. The (2-3020-022) pressure testing kit is used at the end of the installation to test the system
while the (2-3020-025) Repair Tool Kit is used if you ever need to repair a collector.
MISCELLANEOUS - Depending upon your specific job, you will need other plumbing items and materials such as: PVC
valves, stainless steel lag bolts, polyurethane caulk, silicone spray, pipe straps, black electrical wire ties, electrical wire
nuts, 18ga-22ga sensor wire, 12ga-14ga electrical wire with ground, Teflon tape, concrete anchors and screws, electrical
conduit, etc. Be sure to use quality products that will withstand direct sunlight year after year.
NOTE: While this manual explains how to install Heliocol Solar Panels properly in typical situations, it cannot address
all the unique or individual circumstances possible. If you have any installation questions, contact your Heliocol
Representative for assistance. As the installing contractor, you are responsible for exercising good judgment when
installing Heliocol Systems to protect the long term integrity of the collectors as well as the mounting surfaces.
• Flat head and Phillips head screwdriver
• Power drill with bits, 5/16” and 7/16” sockets
• Pipe cutter or hacksaw
• Garden hose
• Channel lock pliers
• Caulking gun
• Ladder
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

PARTS BREAKDOWN -6
5. Parts Breakdown.
PART NO. DESCRIPTION 2-1045-001 2-3045-001 2-3045-003 2-3020-022 2-3020-025
2-1060-002 Top Gator Clamp 2
2-1410-004 Panel Clamp with Gasket 2 2 2
2-1410-005 Pipe Connector 2 4
2-1410-003 End Cap 2
2-1060-001 Bottom Gator Clamp 2
1-5115- 023 ½” Ball Valve 1
2-3020-001 0-60 PSI Pressure Gauge 1
2-2015-101 Pressure Test “T” Assembly 1
2-1410-007 Pin Insert Tool 1
2-1410-008 1/4” Chisel 1
OTHER INSTALLATION COMPONENTS
2-1410-023 Vacuum Breaker 2-2015-010 PVC 2” Check Valve
2-2000-015 Pipe Clamp 2-2015-064 Two-Way Ball Valve
1-5060-011 Lag Bolt 2-2015-065 Three-Way Valve
2-1020-004 Drill Bit 2-1410-017 Gasket for Panel Clamp
2-1120-001 Repair Plugs 1-5060-021 3/8” X 4” Stainless Steel Lag Bolt
2-1060-002 2-1410-005 2-1410-013
2-2015-101
PRESSURE TEST “T”
ASSEMBLY KIT
2-1060-001 2-1410-004
2-1410-008
1/4” CHISEL
1-5115 - 023
1/2 “ BALL VALVE 2-1410-007
PIN INSERTION TOOL
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar
HC-0110 SHORT
ALLIGATOR CLAMP
HC-0110 LONG
ALLIGATOR CLAMP
HC-0110 SHORT
ALLIGATOR CLAMP
HC-0110 LONG
ALLIGATOR CLAMP
2-3020-001

6. Solar Panel Layouts & Hydraulics.
SOLAR PANEL & LAYOUT HYDRAULICS -7
Shown below are the 5 most common solar collector installations.
Fig. 6.1 - SINGLE ROW
Fig. 6.2 - DOUBLE ROW
Fig. 6.3 - SINGLE ROW SPLIT FEED
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar
Fig. 6.1 - SINGLE ROW
Fig. 6.2 - DOUBLE ROW
Fig. 6.3 - SINGLE ROW SPLIT FEED

6. Solar Panel Layouts & Hydraulics. - Cont.
SOLAR PANEL & LAYOUT HYDRAULICS -8
RETURN
FEED
END CAP END CAP
END CAP
FEED
END CA
P
END CAP
RETURN
END CAP END CAP
END CAP
FIGURE 5.5
SERIES/PARALLEL FEED
FIGURE 5.4
SERIES FEED
Shown below are the some common solar collector installations.
Fig. 6.4 - SERIES FEED
Fig. 6.5 - SERIES/PARALLEL FEED
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar
Fig. 6.4 - SERIES FEED
Fig. 6.5 - SERIES/PARALLEL FEED

SOLAR PANEL & LAYOUT HYDRAULICS. -9
Whenever possible, the largest panel (HC-50) should be used. This will:
However, unique roof designs may require a combination of different size collectors to best cover the roof area.
6. Solar Panel layouts & Hydraulics. - Cont.
PANEL SIZE
HC-8 1’ x 8’
HC-9.5 1’ x 9.5’
HC-10.5 1’x10.5’
HC-12.5 1’x12.5’
HC-30 4’x8’
HC-38 4’x9.5’
HC-40 4’x10.5’
HC-50 4’x12.5’
MODEL # MAXIMUM PER ROW
HC-30 12
HC-40 10
HC-50 8
Reduce your total collector cost.
Reduce labor and installation material cost.
Reduce the length of the solar array.
Reduce the number of roof penetrations.
Produce a more attractive installation.
·
·
·
·
·
ROOF ORIENTATION - Ideally, collectors 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 collector should never be installed on a
north roof without a reverse rack in the northern hemisphere.
CHOOSING THE RIGHT SIZE COLLECTOR - The roof space available to you will determine which model collector to
use. Since Heliocol manufactures collectors in eight different sizes, you have great flexibility in what you can design. The
eight panels sizes are:
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. 6.1, page 7. However, there are recommended limits to the number of panels that can
be installed this way to achieve even flow throughout the array. The maximums are:
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 as in
Fig. 6.2, or the single row split feed layout as in Fig. 6.3, page 7. Of course, the double row can also be used for smaller
installations when space is a problem.
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

SOLAR PANEL & LAYOUT HYDRAULICS. -10
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).
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 example: If you are installing (10) HC-40 panels, your pump must be able to deliver 40 GPM to the solar array. These
flow rates may be exceeded by as much as 100% without any detrimental impact on the performance of the system. 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 high
roof, or a large number of panels. If you are not sure what your pump flow rate is, consult your Heliocol representative
or pump manufacturer for the pump’s flow characteristics.
For larger flow rates, consult your Heliocol 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 wit 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 movement and to assure a
professional looking installation.
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. Occasionally, the use of (2) 45-degree fittings will eliminate a 90, but it is not necessary to always
use them as this will run up the expense of your materials.
6. Solar Panel layouts & Hydraulics. - Cont.
MODEL # MINIMUM FLOW
HC-10.5 1 GPM
HC-12.5 1 GPM
HC-30 3 GPM
HC-40 4 GPM
HC-50 5 GPM
FLOW RATE MINIMUM PIPE SIZE
0 to 30 GPM 1½”
31 to 50 GPM 2”
51 to 70 GPM 2½”
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

SOLAR PANEL & LAYOUT HYDRAULICS. -11
BALANCED FLOW - When you have to split a solar system as in Fig. 6.2 or Fig. 6.3, page 7, 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 Heliocol 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 ares of the country where freezing conditions occur. (The Heliocol
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 (2-1410-023) is installed on the solar feed line above the non-positive three-way valve as
shown in (Fig. 13.1, page 22). (Non-positive means that the valve allows for water to drain back through the valve even
while in the off position. If you have 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.
Instead of installing and end cap (2-1410-013) at the end of the header, you would place a pipe connector, and (2-1410-
005) 1½” slip x 1½” threaded PVC reducer bushing, along with a ½” Boiler Drain 1-5115-017. These valves should be
opened when shutting down the system for the winter months or when freezing conditions are possible. Your Heliocol
representative can assist you with the parts necessary for the manual drain down installations.
Install (2) SS Screws (2-1020-006) to secure gator top to gator bottom assembly.
6. Solar Panel layouts & Hydraulics. - Cont.
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

CONNECTING THE SOLAR PANELS TOGETHER. -12
7. Connecting the Solar Panels Together.
Later on in this installation manual you will be instructed to connect the collectors together using plastic panel clamps
(2-1410-009). When connecting collectors together, follow the directions outlined below:
NOTE: On soft roof surfaces or lesser quality asphalt shingle an EPDM or aluminum pad underneath the panel clamp
may be necessary to eliminate possible wear.
Place two collectors next to each other. The spacer bars that hold the individual riser tubes together should be facing
down. Lay a plastic panel clamp (2-1410-004) top, bottom, gasket, and clip where the two headers meet. (Fig. 7.1-A).
Place the bottom half (see Fig. 8.1) of the plastic panel clamp (2-1410-004) under the collector header with the hook
portion of the panel clamp facing the inside of the collectors. (Fig. 7.1-C).
Clean the groove of both headers.
Seat both headers together by inserting the gasket into the opposite header groove and placing the ends of both
headers into the open space in the panel clamp bottom. (Fig. 7.1-D).
Use channel lock pliers to tighten the clip grip by squeezing it with reasonable force until it seats flush or even
slightly farther so it cannot slide out of its position. (Fig. 7.1-G).
Spray the gasket with silicon and insert it into the groove of one of the headers. Make sure that the gasket is fully
seated into the header groove by pushing firmly with your thumb all the way around the gasket. (Fig. 7.1-B).
Interlock the top half of the panel clamp with the hook on the bottom half. Swing top half over top of collector
headers. Squeeze the top and bottom portions of the panel clamp together using channel lock pliers and lock both
halves of the clamp together using the locking clip. (NOTE: Slide large end of locking clip over small end of plastic
panel clamp assembly). (Fig. 7.1 - E & F).
Insert locking clip into slots on slide locking clip.
Use this same procedure to connect both top and bottom headers of the collectors.
1.
4.
2.
SEE FIGURES ON NEXT PAGE
5.
7.
3.
6.
8.
9.
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

CONNECTING THE SOLAR PANELS TOGETHER.-13
7. Connecting the Solar Panels Together. - Cont.
Fig. 7.1
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

Fig. 8.1
Panel Header (Top)
2-1410-018 L Latch
2-1410-020 T Panel Clamp Top 2-1060-002 Alligator Clamp
2-1060-001 Alligator Clamp
2-1410-015 Panel Clamp Bottom
2-1410-017 Gasket
The beauty of the “gator clamp” installation method is its simplicity it can be used on just about any type of roof or rack
installation.
For rack systems, asphalt shingle roofs, or tile roofs follow these simple steps:
8. Mounting the Solar Panels Using Gator Clamps.
Snap a chalk line across the roof or rack where you want the top edge of the collectors to be located. The panels
should slope slightly down toward the feed end of the array for proper drainage.
Since normal horizontal expansion and contraction of an array of panels takes place every day as panels heat up
and cool down, it is preferable to lock the center of each array in place so that the expansion and contraction takes
place evenly to the left and right of this center point. The center panel of an array may be locked in place by locating
the gator clamps on that panel adjacent to the left and right of one of the header ribs (see Fig. 8.3, page 15). These
gators should be attached using (2) lag bolts as opposed to (1). Do not use this procedure more than once on any
array of panels.
Position the first gator clamp on the chalk line 6” from the top corner of the first panel. The first panel will be the one
that is connected to the feed line at the bottom header.
Subsequent gator clamps should be spaced out evenly along the chalk line every 24”. Each gator clamp can be
located anywhere along the top header to match up to the spacing of the roof rafters as long as there is a 2” space
between the edge of the gator clamp and the ribs on the panel header that exist every one foot. This allows
for horizontal expansion and contraction. For barrel tile roofs, each gator clamp needs to be positioned so that it is
centered on the top ridge of a tile.
1.
4.
2.
3.
MOUNTING THE SOLAR PANELS USING GATOR CLAMPS. -14
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

MOUNTING THE SOLAR PANELS USING GATOR CLAMPS. -15
8. Mounting the Solar Panels
Using Gator Clamps. - Cont.
Apply ample sealant to both the bottom and top of the lower hole on the bottom portion of the gator clamp. (Fig.
8.4-A). Position the bottom portion of the gator clamp perpendicular to the chalk line with the lower hole being
placed right on the chalk line. Lag the gator to the roof through the lower hole using a 1/4” x 4” 1-5060-011 S.S
lag bolt. (Fig. 8.4-B). For barrel tile roofs, place (4) 2-1020-005 barrel tile spacers underneath each gator clamp by
inserting the 4’ of the barrel tile spacer into the four corners of the bottom of the gator clamp. (Fig. 8.5).
The bottom of the gator is designed to grip the roof’s surface to avoid rotation back and forth. However, if the roof
surface is particularly hard or slick, use an additional lag bolt in either the top or center hole.
To ensure proper spacing, hang the top headers of panels in the bottom portion of the gators attached to the roof
as you go. Once again, be sure gator clamps are at least 2” away from each ridge along the heading. (Fig. 8.4-D).
Once all gators are properly lagged to rack or roof surfaces, and all the collectors are hung in place, connect the
top headers of each collector using (2-1410-004) panel clamps. Snap the top portion of each gator clamp over the
panel header onto the bottom portion of each gator clamp by pushing down firmly. (Fig. 8.4-C).
Install (2) SS Screws (2-1020-006) to secure gator top to gator bottom assembly.
Attach the bottom headers of the collectors with (2-1410-004) panel clamps.
Locate and mount the gator clamps (2 each) along the bottom header, aligned with the upper header gators. The
bottom gator should be installed allowing a large gap on the to allow for contraction of the collectors.
Attach feed and return lines following Heliocol’s published guidelines.
The corners of where the feed and the return are located should be fastened down by pipe straps that are also
supporting the pipe.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Fig. 8.2 Fig. 8.3
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar
NOTE: Typical residential mounting
planshown.Foradditional mounting
options for commercial installations
please refer to addendum provided
by manufacturer’s engineering
department.

MOUNTING THE SOLAR PANELS USING GATOR CLAMPS. -16
8. Mounting the Solar Panels
Using Gator Clamps. - Cont.
Fig. 8.4
NOTE: *Additional gator clamps are required for surfaces with a pitch of 10/12 or greater.
NOTE: To allow for vertical expansion and contraction, any gators installed on the bottom header must be positioned
so that the header is in the middle of the cradle. (Fig. 8.6).
Fig. 8.5 Fig. 8.6
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

MOUNTING THE SOLAR PANELS ON A FLAT ROOF.. - 17
9. Mounting the Solar Panels On A Flat Roof.
FIBERGLASS COATED, METAL, OR SHINGLED FLAT ROOF - If you have one of these three types of roofs with at least
3” of slope down the panel length, you can use the gator clamp method previously described. Use liquid adhesive to
secure the (2-1060-001) gator clamp to the roof, or consult A.H.J. or engineer of record to make sure installation meets
code regulations.
NOTE:
Whenever unglazed solar collectors are installed on a rack, a substrate should be mounted on the rack prior to
mounting the panel. This eliminates heat loss and stress created by wind blowing on the back side of the rack.
However, if this wind is eliminated by other site specific conditions, (e.g. windbreaks or fences) substrates are not
necessarily required.
There are all types of flat roof surfaces, and as the installing contractor, you are responsible for making sure that
the installation will not damage the roof surface. If, for example, you have a very soft or rubberized roof surface,
you’ll want to protect the roof surface with some type of substrate.
Please note that not all flat roof installations are the same. Please contact
your local roofing contractor to ensure your meeting all local codes.
If you have chosen a flat roof to mount the solar panels, it is recommended not to penetrate the surface with a lag bolt.
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar

ASSEMBLY OF ROW SPACER KITS. - 18
10. Assembly of Row Spacer Kits.
HC-RSK
NOTE: When gluing the (2-1410-005) CPVC pipe connectors, it is necessary to use good quality “multi-purpose” cement.
WARNING - THIS SHOULD NOT BE DONE BETWEEN THE HEADER AND THE FIRST
SPACER BAR AS IT WILL POSSIBLY PULL THE RISER TUBE OUT OF THE HEADER. THE
HELIOCOL WARRANTY DOES NOT COVER LEAKS OCCURRING FROM THIS TYPE
OF INCORRECT INSTALLATION. A ROW SPACER KIT SHOULD BE USED FOR THIS
SITUATION.
NOTE: Obstructions smaller than 6” can be circumvented by snapping the panel
riser tubes out of the spacer bar and spreading them around the obstructions.
(see Fig. 10.2).
Flexible riser tubes are snapped
out of the spacer bars to go
around small obstructions.
When you need to install panels over an obstruction larger than 6’ wide, or if the obstruction is less than 1’ from a panel
header, you’ll need a row spacer kit to circumvent the obstruction.
1.
2.
3.
4.
Connect (4) of the (2-1410-005) pipe connectors to the headers of the collectors to be connected with a (2-1410-004)
plastic panel clamp using the same procedures outlined in the section on connecting solar collectors together on
page 12.
Cut two lengths of 1-½” PVC pipe long enough to cement the (2-1410-005) pipe connectors on each collector to each
other.
Cement the PVC pipe to the pipe connectors as shown in Fig. 10.1.
If the distance between the collectors is over 4’, a 2” pipe clamp should be used on both pipes to prevent sagging.
Fig. 10.1
Fig. 10.2
INSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
©2014 UMA Solar
2-1410-004
2-1410-004
2-1410-005 2-1410-005
1 1/2” PVC PIPE

CONNECTING THE SOLAR PANELS TO THE FEED & RETURN LINES - 19
11. Connecting the Solar Panels
to the Feed & Return Lines.
1.
2.
3.
4.
5.
6.
The feed line will be connected to the low end of the bottom header, which should be the corner farthest from the
pool pump. The return line will be connected to the top header on the opposite end of the array. This gives the heated
pool water the shortest route back to the pool.
The (2-1410-013) end caps will be located on the corners of the solar array opposite of the corners where the feed line
and return lines will be. Attach the (2-1410-013) end caps using the (2-1410-004) plastic panel clamp as described
on page 12. (See Fig. 11.2-A).
Attach the (2-1410-005) pipe connectors to the corners of the array where the feed and returns lines will be using the
(2-1410-004) plastic panel clamp. (See Fig. 11.2-B).
The (2-1410-005) pipe connector allows a 1½” PVC Street 90 to be glued directly into the socket, or a 2” PVC 90 to be
glued on the side. CPVC glue should be used when attaching PVC fittings or pipe to the pipe connectors to provide
for a durable connection. A 90 PVC fitting and vertical pipe run of at least 5’ should always be attached to the return
line pipe connector to allow for lateral expansion and contraction of the return line pipe run.
Connect the feed and return pipes using good plumbing techniques.
Attach the (2-1410-013) end caps on the corners opposite the feed and return lines using the (2-1410-004) panel
clamps.
Fig. 11.2
INSTALLATION MANUAL HELIOCOL SOLAR POOL HEATERINSTALLATION MANUAL HELIOCOL®SOLAR POOL HEATER
Fig. 11.1
Header
2-1410-005 CPVC Pipe Connector
2-1410-013 End Cap
2-1410-004 Panel Clamp
©2014 UMA Solar
1 ½” PVC Stub