Zodiac NOOSA REEF User manual

NOOSA
REEF
Oval Instruction Manual
2007-2008
TToobbeeuusseeddiinn
ccoonnjjuunnccttiioonnwwiitthh
tthheeDDVVDD..

MASTERING THE ELEMENTS
Renowned worldwide for the quality and reliability of its products in the aeronautical and
marine sectors, Zodiac has now brought its expertise to swimming pools, to bring you a full
range of pools, automatic pool cleaners and water treatment systems.
Backed by Zodiac technology, expertise and experience, Zodiac brings you the reassurance of
top quality equipment in terms of both design and performance.
A real guarantee of efficiency and peace of mind!

INDEX
1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Site selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Site preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Positioning the channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Noosa Reef Deep End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Deep End excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Deep End Channel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Deep End part quantities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Deep End parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Deep End frame assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Positioning the channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Liner installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembly of Top Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Skimmer box Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Backfill requirements for Noosa Reef inground installation . . . . . . . . . . . . . . . 54
Pool care questions and answers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Warranty Terms and Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

CUSTOMER LETTER
2
Dear Customer,
Congratulations! You are now the owner of an innovative Zodiac swimming pool that will allow you to make the most
of your summer.These instructions will help you easily and correctly install your Zodiac modular pool. Read them
carefully and make sure you understand them before you proceed. Before you begin, here is some additional
information that will help you through the installation process: Finding the right location for your pool is of the
utmost importance.To find the right spot, you must ask yourself a number of questions. How far is the property line?
Are there electrical lines overhead or underground? What about telephone lines, or gas and water pipes? You must
also consider the slope, soil composition and drainage on your property as well as the climate, prevailing winds and
available sunlight.
Minimum bearing capacity of ground under pool is to be 80k Pa.This may need an engineers soil test to verify.
Unstable soil may result in the pool moving and not remaining level.
Before commencing the installation of your pool, ensure that you have complied with council requirements and
obtained the necessary council permits.
Installation requires a minimum of 2 people and the amount of time varies according to the size and model of the
pool you have. However, it generally takes about 8 hours for an oval pool (not including the time required to prepare
the site and fill up the pool).
We also suggest installing your pool on a sunny and windless day. Installation of the liner on a warm day will make it
easier to fit.
Before starting to use your pool, it is important to know all about water treatment.We also recommend that you
check the fastenings (bolts and screws) every year to make sure that all of the parts are in good shape.
Ensure that the water level in your pool is maintained at the correct level for safe operation of the filtration system.
Never leave your pool empty.This can result in severe damage to your pool liner.
Never dive or jump into a modular pool and never walk or sit on the top deck as it is very dangerous and serious
injuries may occur. Failure to adhere to instructions concerning maintenance, safety, assembly, start-up and use could
pose serious health risks, especially to children.Your pool is designed to provide years of enjoyment, as long as it is
carefully and correctly installed and maintained. Read and make sure you understand the instructions before you start.
Work step by step, and take your time.
If you encounter any problems during installation or if you require additional information, please contact the Zodiac
retailer/dealer
or contact Zodiac Group Australia Pty Ltd
by phone [phone] or by fax [phone]
Happy swimming!
POOL WARRANTY REGISTRATION
Your pool is warranted by Zodiac Group Australia Pty. Ltd. It is advisable to register your pool within 30 days of purchase.
Complete and return your pool warranty registration card to Zodiac Group Australia. If you did not receive a warranty
registration card you can register your warranty online at http://www.zodiac.com.au or contact your pool dealer.
POOL CARE
Like a car your pool will remain looking its best if washed occasionally.As water is splashed out of your pool onto the decks,
verticals and wall, the water will evaporate leaving behind deposits of concentrated salts.This can be prevented by washing your
pool with soapy water then rinsing with fresh water to remove all the salts from the metal components of your pool, even
underneath the decks (rinsing with fresh water will help, but soap will give a better result).

SAFTEY FIRST
3
SAFETY FIRST!
NEVER UNDER ANY CIRCUMSTANCE stand, walk or sit on the top decks. Any fall could
result in spinal or neck injuries and/or possible drowning.Always enter the pool via the step entry system
or ladder provided with your pool. Do not jump or dive.
ALWAYS MAKE SURE THAT CHILDREN ARE SUPERVISED whilst in the pool area
and make sure that pool fencing and gates are adequate barriers to your children when the pool is not
being supervised.
ALWAYS FOLLOW THE INSTRUCTIONS contained in this manual. Incorrect installation can
lead to product failure and warranty voids. Please respect that your pool can be holding up to 60 tonnes
of water! Make sure that when joining the pool wall all bolts and nuts are used and tightened/ correctly.
ALWAYS KEEP ELECTRICAL HAZARDS AWAY FROM POOL AREA.
NEVER INSTALL YOUR POOL WALL IN WINDY CONDITIONS.
NEVER LIFT WALL CARTONS OR LARGE POOL CARTONS by yourself.These cartons
require two people to lift. Remember, lift with your knees bent and not with your back!
KEEP POOL CHEMICALS OUT OF REACH OF CHILDREN AT ALL TIMES.

INTRODUCTION
4
INTRODUCTION
Congratulations on the purchase of your new Zodiac pool.This pool is the product of more than thirty years continuous
development.The pool installation procedure has been set out in easy to follow step by step instructions with illustrations.
Please take the time to read your owners manual thoroughly before and during installation of your pool.Your warranty will be
void if the procedures in this manual are not followed. If you are having your pool installed by a professional installer it is your
responsibility to inspect the work at all stages to ensure that each step being undertaken complies with ALL instructions. Please
also read and follow the instructions relative to all accessories, i.e. pumps and filtration prior to installation.
IMPORTANT POINTS
LOCAL REGULATORY BODIES
When installing a new pool, you must comply with your local safety regulations and codes.As these regulations vary from
council to council it is a must that you check with your local council what the requirements for your site are, i.e. fencing
requirements. COMPLYING WITH LOCAL REGULATIONS AND CODES ARE YOUR RESPONSIBILITY.
CONTRACT INSTALLATIONS
Proper installation procedures are essential to ensure the best performance and durability of our pools in service. Zodiac are
not affiliated with any pool installers and we cannot accept any responsibility for problems caused by incorrect installation
procedures. It is strongly recommended that only reputable licenced and insured professional installers undertake the work
ensuring that it complies with the instructions contained in this manual. (not applicable in all states)
BEFORE YOU START
Before attempting pool installation, please make yourself familiar with the DVD and this manual. Make sure that the instructions
relate to the correct pool.Take the time to study the step by step procedures; an extra half an hour now could save
complications later on.
Allow plenty of time for installation, start early in the day.The installation process is made up of six defined stages.
1. Site selection
2. Site preparation
3. Frame installation
4.Wall installation
5. Liner installation
6. Skimmer box installation
Great care should be taken with all stages. If the site preparation and cross channel installation are not done with care and/or by
following the instructions contained in this manual the structural integrity of your pool may be reduced.
Take time, check and re-check.
Check lists can be found at the start of each frame installation section. Do not commence installation with parts missing.
Ensure that you have all the required tools on hand before commencing and make sure that you have help on hand at all times.
IMPORTANT
This pool has been designed and engineered (which complies with an approved engineer certificate). Installation of the
pool should be as shown in the assembly manual.Any deviation from this manual could cause serious injury and void warranty
of the pool.

TOOLS REQUIRED
5
CEMENT
Clear plastic hose
Water
Cut a piece of 9mm tubing around 20cm long,
fill the tubing with water. This can then be used
to find the level between one side and the other.

1
2
POOL LINER
PARTS LIST
6
Ref. Part Model 2012 2412 2315 2715 3015 3815
Size 3.66 x 5.94 m 3.66 x 7.08 m 4.57 x 6.85 m 4.57 x 7.99 m 4.57 x 9.13 m 4.57 x 11.41 m Carton
A1 Radius/ curve long top deck 15’
PSL 725-001-R - - 10 10 10 10 Deck carton
Radius/ curve long top deck 12’ 8 8 - - - - Deck carton
PSL 725-001-R12
A2 Straight side short top deck 4 6 4 6 8 12 Deck carton
PSL 725-001-0
BResin upright ends (1) 1-6 1-6 1-8 1-8 1-8 1-8 Vertical carton
PSL 725-002-52
Resin upright sides hollow (2) 2-6 2-8 2-6 2-8 2-10 2-14
Open end exposed
PSL 725-002-52ov
CArtium joiner plate 12 14 14 16 18 22 ACC Box
P20850
DLong pin 6 8 14 16 18 22 ACC Box
P1000114
EEZ-lock atrium 13 15 15 17 19 23 ACC Box
P1000116
FWall channel round end section 1-8 1-8 1-10 1-10 1-10 1-10 Rail Box
P13056UKIT
Side section (2) 2-4 2-6 2-4 2-6 2-8 2-12
P1294215
GWall with skimmer and
returns outlets 1 1 1 1 1 1 Wall carton
PWAL403 PWAL406 PWAL404 PWAL405 PWAL409 / 410
HLiner 1 1 1 1 1 1 Liner
Brookstone PH40BBST PH40BBST PH40BBST PH40BBST PH40BBST PH40BBST
-121952 -122352 -152252 -152652 -153052 -153852
Brookstone Deep End N/A PH40BBST N/A PH40BBST PH40BBST PH40BBST
-1223X52 -1526X52 -1530X52 -1538X52
Opal PH22TPSL PH22TPSL PH22TPSL PH22TPSL PH22TPSL PH22TPSL
-121952 -122352 -152252 -152652 -153052 -153852
Opal Deep End N/A PH22TPSL PH22TPSL PH22TPSL PH22TPSL PH22TPSL
-1223X52 N/A -1526X52 -1530X52 -1538X52

PARTS LIST CONTINUED
7
Bolt Identification
Use Specifications
Wall Joint 1/4” x 3/8” Roofing bolt (Stainless)
1/4” x 9/16” Flat washer (Stainless)
1/4” Hex nut (Stainless)
Joiner Channels 1/2” x 1” Bolt (High Tensile)
Female to Male 1/2” Hex nut (High Tensile)
1/2” x 11/8” steel washers
P Post 12mm x 100mm (High Tensile)
(P Post to Female) 12mm Hex nut (High Tensile)
Ref. Part Model 2012 2412 2315 2715 3015 3815
Size 3.66 x 5.94 m 3.66 x 7.08 m 4.57 x 6.85 m 4.57 x 7.99 m 4.57 x 9.13 m 4.57 x 11.41 m Carton
IBase crown
PSL 725-007 6 6 8 8 8 8 ACC Box
JSeal cap 12 14 14 16 18 22 ACC Box
PSL 725-006
KP Post R 6 8 6 8 10 14 Separate
LJoiner channel Female E 6 8 6 8 10 14 Channel
P160563
D1 Joiner channel Male D 6 8 6 8 10 14 Channel
P160564 carton x1
D1 Joiner channel Female C 3 4 5 7
P160562
Green
Orange
Yellow
Green

ENLARGED VIEW OF COMPONENTS
8
F2
B2
K
CF1
G
B1
A2
J
D2 EA1
L
I

SITE SELECTION
9
B. CLEAR AREA
Clear the area of anything which may damage the pool. Remove any grass, weeds, stones, asphalt, tarred paper, poison, nut grass or
weeds (NOTE If weed killer is used wait 3 days after spraying before installing your pool, some poisons will adversely effect the
liner). Remove all dead plants as part of site preparation.All of these may puncture the pool liner.
Roughly level an area allowing at least 30cm extra distance around the pool as shown.If a sloping area is used, dig away dirt from
high side.The area to clear is shown on the pool layout plan.Take note of where the lowest point is and remove soil to this level.
Pool Area
Cl
eare
d
A
rea
additional
cleared area
DO NOT FILL IN
THIS AREA
DIG EARTH AWAY
MAKE LEVEL
A. DETERMINE POOL LOCATION
Look over the various pool locations shown at right
1.TERRAIN
Look over your property for the most ideal pool
location.A large area is best. If you have no flat area
large enough for the pool then try to pick a spot
where you would have the least amount of digging to
do. Do not install in a major water drainage
depression or sewer drain field. Ground area around
the pool foundation should be level for 900mm out
from base of pool.
2. CONVENIENT ELECTRICAL OUTLETS
Your pump and other accessories are operated by
electricity. If there are no outside electrical outlets,
you must have them installed by a qualified electrician.
3. OVERHEAD ELECTRICAL WIRES
The pool should never be placed directly under any
overhead powerlines for precautionary measures.
4. UNDERGROUND CABLES – CHECK
WITH LOCAL AUTHORITIES!
Before you start digging into the ground to level the
surface, it would be wise to check with your council
as to the location of any underground lines or pipes.
Dial 1100
5.TREES
Trees and their occupants are not the best of friends with swimming
pools. Falling leaves, branches and sap can be a constant problem in
keeping the pool water clean (along with bird droppings and insects
falling into the pool).These materials will necessitate cleaning your
filter unit more often.The further away from the tree, the better for
your pool.
NO
NO
NO
YES
DO NOT BUILD UP SURFACE
OR LOW SPOTS
ALWAYS DIG AWAY TO
LEVEL THE SURFACE
30cm
30cm

Find a site where the ground is stable, level and well drained. Once you have selected your site, trace the
lines in accordance with the above diagram. Each line to be traced in is clearly identified by letter
A,B or C, which corresponds to a different length, according to the size of your pool.(Refer to chart)
Note: Line B is about 30.5 cm (12”) longer than the diameter of the assembled pool (see illustration)
This will allow you more leeway to work.
When you choose the appropriate site for your
pool, make sure you allow for the distance
between the pool and property line as requires
by law in your municipality.
Important: Make sure the pool wall is at least
1 M from the fence so that the substructure can
be installed.
B
BB
B
C
C
C
AA
SITE PREPARATION
10
STEP 1.
STEP 2.
Model 2012 2412 2315 2715 3015 3815
Size 3.66 x 5.94 m 3.66 x 7.08 m 4.57 x 6.85 m 4.57 x 7.99 m 4.57 x 9.13 m 4.57 x 11.41 m
A & B 2 m 2 m 2.5 m 2.5 m 2.5 m 2.5 m
C 2.6 m 3.9 m 2.9 m 3.9 m 5 m 7.5 m
Dimensions

Using the steel pegs at the centre of both
circles attach the end of the measuring tape
to the steel pegs.
Using the tape measure and the can of spray
paint mark out the area to be cleared
and levelled for your pool.
A
A
B
B
B
B
SITE PREPARATION
11
STEP 3.
STEP 4.
Model 2012 2412 2315 2715 3015 3815
Size 3.66 x 5.94 m 3.66 x 7.08 m 4.57 x 6.85 m 4.57 x 7.99 m 4.57 x 9.13 m 4.57 x 11.41 m
A & B 2 m 2 m 2.5 m 2.5 m 2.5 m 2.5 m
C 2.6 m 3.9 m 2.9 m 3.9 m 5 m 7.5 m
Dimensions

Remove any grass sod and tree roots from the
area you have just outlined.
Rake out pebbles, roots and other debris.
SITE PREPARATION
12
STEP 5.
STEP 6.

Hint:
Attach the spirt level to the
straight edge using pvc adhesive tape.
Materials:
- Straight wood plank
Locate the lowest point and level the ground.
You should never fill in holes. Level out bumps instead
SITE PREPARATION
13
LEVEL POOL AREA
Unless you have access to a surveyor’s level,
the best, most accurate way to level
the ground is with a straight
plank (100mm x
50mm will do but it
should be straight)
and a spirit level (fig 2.).
Find the lowest spot within
the pool area and level the
ground to the lowest point. Dig away
the high areas – do not fill in the low
areas .
Machine excavated sites are rarely level. It is still
necessary to hand trim to ensure that the
framework will be level.The most critical areas
are the pool perimeter and cross channels.The
pool floor should be generally level but the sand
base can be used to fill any low spots. Note: If
not level, pool wall could buckle or crease.
BE SURE: recheck the level of the entire pool area. The success of installation depends upon how well this is performed.
Once the site has been cleared and levelled it is time to start assembling the base channels and P.Posts.
IMPORTANT NOTE:
Some noxious weeds, such as onion weed can grow up through the liner material damaging your pool liner.
To guard against this we reccomend that you treat the area with a suiteable weed killer(poison). Please insure the weed killer you
use is a recognised product and will not have any detremental effects on the vinyl material used in your pool liner.
STEP 7.
FIG 2
Pool

FRAME INSTALLATION
14
STEP 8.ASSEMBLY
Identify the P. posts, joiner channels (female E), joiner channels (male D) and joiner hardware (nuts,bolts & washers) required
for your size of pool.
Lay these components out on the ground in their correct order and assemble them as per the instructions in step 9. below
NOTE: Refer to page 17 for the layout of the size of the pool you have purchased.
NOTE:
1. Diagram shows assembly for a 3706mm
wide section.
2. 4616 wide pools have 5 joiners in each
section (2 x E joiners , 2 x D joiners and
1 x C joiner
STEP 9. FRAME ASSEMBLY
Once the joiner channels have been assembled and bolted together the channel assembly is to be attached to the P.Posts.The same
components are used for both 3.6m wide pools and 4.5m wide pools, except a C Female joiner is added to the 4.5m pools.The
joining configurations are shown below.
4.5m wide
3.8m wide
Bolt
Nut
Washer
Joiner channel male
Joiner channel female
D Male D Male
E Female
Exploded view
E Female
D Male D MaleE Female E Female
D Male D Male C FemaleE Female E Female

POSITIONING THE CHANNELS
15
NB. The instructions shown refer to a 7.08 x 3.66 pool refer to page 17. for the measurements for the other pools.
2100mm
1140mm 1140mm 1140mm
STEP 10.
Once the channels have been assembled and all of the nuts and bolts have been tightened, It’s time to position the assembled
frames into the pool site. Place the first assembled channel across the width of the pool at a point 2100mm from the end of
the cleared area.
NOTE:
2100 Refers to a 3.66m Pool, 2540 refers to a 4.57m pool.
STEP 11.
Place the 2nd and remaining channels at a point 1140mm from the adjacent channel.
NOTE: 1140mm measurements are taken from the centre of the channels

POSITIONING THE CHANNELS
16
Refer to page 21 for the end radius of each pool.
CHANNEL POSITIONING
X
B
A
B
B
A
B
X
7.08 X 3.66 m- 24200 Lt
5.94 X 3.66 m- 19800 Lt
9.13 x 4.57 m- 38000 Lt
7.99 x 4.57 m
A= 3856 mm
B= 1140 mm Centres
C= 2100 mm
X= 4766 mm
B=1140 mm Centres
Y= 2540 mm
Y
C
C
Y Y
Y
11.41mx 4.57m- 48500 Lt
X
B
B
X
6.85mx 4.57m- 27650 Lt
Outside measurement Outside measurement
STEP 12.
Note:The width measurements (A or X) can have a variance of + or - 5mm.

POSITIONING THE CHANNELS
17
AB
Steel peg
Steel peg
String line
STEP 13.
To check the alignment of the P. posts, position a string line along the back of the posts between two (2) steel pegs.
(Points A and B) if the posts are not correctly aligned they need to be tapped back or forward until the back of each post is
correctly aligned with the string line.
Measure the two intersecting axis to ensure that the two straight sections are parallel.
The measurements of the points A to D and B to C must be equal.
AB
CD
STEP 14.
Once these steps have been completed you need to check the diagonal measurements of the pool frame.

POSITIONING THE CHANNELS
18
DEPTH 100 mm
Width 75 mm
1140 mm
250 mm
Pool wall
Positionthe concrete blocks into excavated area.
The depth ofthe
precast block 75 mm
Side view
Ground Level
Above view
Depth ofconcrete
mix 150mm
250 mm
75mm Concrete block
NOTE- If using cement mix instead of concrete blocks, the cement mix is put in place after the channels have been positioned
and levelled.
STEP 16. INSTALLING FRAMES
Frames should be installed in such a way that no horizontal part of the P Post is situated higher than the existing ground level.
All P Posts must be level, as well as being level with all other adjacent P Posts.When checking the level of individual P Post it is
important to note that the vertical section of the P Post is not perfectly perpendicular to the horizontal, the level must be found
on the horizontal member of the P Post and not the vertical.The checking of adjacent P Post can be done by placing a level
(if longer than 1.1M) or sufficient straight edge across the top of the adjacent P Post .
THE LEVELLING OF THE P POST IS AN IMPORTANT EXERCISE THAT MUST BE DONE PRECISELY AND
REPEATEDLY UNTIL CORRECT.
NOTE- CONCRETE PADS:The use of concrete blocks or concrete mix at each end of the P Post is critical as it distributes the
load carried by the frames evenly into the soil below. Not using concrete pads will result in the frame sinking into the ground and
disturbing the level of your pool. Pads should be installed as shown below. DO NOT USE HOUSE BRICKS OR BESSER BLOCKS.
All excess areas to be lled with 8.1 wet sand/ cement mix
P Post
Joiner Channels
Existing ground level
Concrete pad
or concrete mix
STEP 15.
When the end channels are in the correct position, spray paint a line on either side of each channel across the pool.This is to
mark out the areas to be excavated.When these areas have been marked out, the channels can be removed from the site.The
marked areas should be excavated to a depth of 100mm x 75mm wide across the pool from one side to the other with a 250 x
250 x 150mm excavation at each end for the positioning of the pre-cast concrete blocks.
An alternative to concrete blocks is to pack a strong sand/ cement/ screenings mix under the back of the channels (Rapid set pre
mix is ideal for this purpose). If you are using the cement mix rather than the concrete blocks, the excavations at the ends of the
channels will need to be dug out to 250 x 250 x 150mm.