Performance+ OKU Panel Solar Pool Heating System -- Installation and User Manual

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EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2019 Optex Solar Pty Ltd. All rights strictly reserved.
EcoOnline Performance+
OKU Panel Solar Pool Heating System
Installation and User Manual - Revised 19/09/2019
Optex Solar Pty. Ltd.
ABN: 88 128 228 884
www.EcoOnline.com.au
email: info@EcoOnline.com.au
© Copyright 2019 Optex Solar Pty Ltd. All rights strictly reserved. This publication is protected by copyright law
and unless otherwise specified is for your personal and non-commercial use only. No part of this publication
may be reproduced or distributed by any process, electronic or otherwise, without the specific written
permission of Optex Solar Pty Ltd. Trademarks appearing in this manual are the sole property of Optex Solar
Pty Ltd or their respective owners. Nothing in this publication shall be construed as granting any express or
implied license to use any intellectual property of Optex Solar Pty Ltd otherwise than for personal and
non-commercial use only. Optex Solar Pty Ltd must not, to the full extent permitted by law, be held liable
for any claim, cost (including legal costs), damage, expense, loss (including fines, penalties, set-offs and
consequential loss) or liability arising from the use (or misuse) of any product described in this
publication, unless expressly provided otherwise in this publication. Information as well as any
products described in this publication are subject to change without notice.
EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
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Contents Click Heading Titles to Navigate Up or Down
EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
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EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
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1 Key Terms
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This manual was written to follow guidelines and recommendations given in:
? AS 3634 - 1989 Solar heating systems for swimming pools
? AS 1170.2 - 2011 (Amend 2 Dec 2012) Structural design actions - Wind actions
? ‘HAZPAK’ produced by the work-cover authority
? AS 3000 (2007) Sections 6.3, 6.4 & 6.5
? AS 1926.1 & 1926.2 (2007) swimming pool safety - location of safety barrier
Please take the time to read this manual before starting any work. Particular attention should be given to text
contained in the following key terms.
Please note EcoOnline has a strong product safety policy; do not install products without reading safety guidelines in
the manual. Please report any product safety issues or near misses to info@EcoOnline.com.au no matter how trivial.
Refers to useful information for the optimal operation of the system
Indicates a SAFETY issue that is likely to cause injury or death if the user does not
follow the instructions.
Indicates a SAFETY issue that may cause injury or death if the user does not follow the
instructions.
Refers to critically important information related to the correct functioning of the
system.
Why? Italic text is optional reading. Gives extra information and reasoning for recommendations that are
non-obvious and/or counter intuitive.
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2 Pre-Installation Suitability and Safety Checklist
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The following outlines mandatory suitability and safety requirements for installing this solar heating system. Please
read carefully, if any of the following requirements cannot be meet the system should NOT be purchased or
installed.
For ground level collector installations the installer MUST check child safety fence regulations
in the relevant state. Under no circumstances should collectors be installed so as to
compromise the effectiveness of a child pool or spa fence safety barrier by providing a
climbable object.
Building regulations vary from state to state and MUST override any instructions supplied in
this manual. It is the responsibility of the purchaser/installer to check that installations
comply with any relevant state laws and regulations.
At present this collector array system is not recommended for installations in cyclonic
regions C or D, or on houses situated on top of hills exposed to strong winds, or on second
story (or higher) roofs. Installations on tiles are for Wind Region A only.
Collectors are to be used with chlorinated (or otherwise sanitized) pool water ONLY. Do not
use collectors to heat fresh (untreated) water due to the potential for Legionaries bacteria
build up.
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been
given supervision or instruction concerning use of the appliance by a person responsible for
their safety. Children should be supervised to ensure that they do not play with the appliance.
Due to the potential of falling from heights, mounting panels on a roof or structure at
heights should only be undertaken by a professional installer, unless you are accustomed
to and confident of performing the work safely. We strongly recommend the installer
invests in roof safety guard rails and a safety harness system, especially for DIY
applications.
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3 Warranties
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EcoOnline™ offers the following Warranties
? 35 year limited Warranty on all OKU collectors
? 2 year Warranty on Reltech Pool Pumps
? 3 year Warranty on Davey Pool Pumps
? 3 Year Warranty on Dontek and Ascon Controllers
See our Terms and Conditions page for further details: www.EcoOnline.com.au/terms-and-conditions
4 System Sizing Guarantee
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Sizing systems is difficult involving a lot of factors which we could get wrong. Hence in addition to the above
Warranties EcoOnline offers a System Sizing Guarantee as follows. If we sized your system (or you use our online
calculator) and you took our advice and you aren’t happy with the system’s performance (heat output), then you can
purchase up to 25% more panels originally supplied by EcoOnline up to two years after your original purchase and
we will ship the items free of shipping charges.
5 Collector Sizing Guide
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An interactive collector sizing calculator and pool water temperature simulator can be found on our website at:
www.EcoOnline.com.au/pool-heating-sizing-calculator
www.EcoOnline.com.au/pool-water-temperature-simulator
5.1 A Word on Transparent Bubble Pool Covers
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EcoOnline recently carried out a full pool heating loading technical study including performance data on transparent
bubble pool covers. We found that while pool covers produce a moderate heating effect by themselves, they
produced a much larger pool temperature boost when used in conjunction with a solar pool heater due to
synergistic effects. So much so that if you’re running a solar pool heater and not using a pool cover you are missing
out on surprisingly large temperature gains - see link below for the summaries:
Customer please note: WARRANTY IS VOID if collectors are installed:
? without a vacuum release valve on the return line,
? or a non-return valve on the solar pump outlet (with 6mm drain hole in flap),
? or if panels are run at pressures other than near zero (max ± 1psi),
? or in a manner that prevents collector from fully draining when the pump stops,
? or if the collectors are installed well below the water level (max 1.5m).
Why? Such installations will expose the collectors to strong fatiguing positive/negative
pressures, and/or stagnant hot chlorinated water on hot days. These situations will have
detrimental effects on the collectors which will limit lifetimes and can also result in
significant shrinkage of the collectors which would put strain on roof attachments.
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www.EcoOnline.com.au/how-warm-can-a-pool-get-with-a-solar-heater-and-cover
So if you’ve used a pool cover before and had disappointing results, we highly recommend you try using a cover
again after you install our solar pool heating system.
6 Pool Chemistry Compatibility Guide
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Incompatible Chemistries
Alternatives Chemistry
? Bromide Based Chlorination
? Any other Chlorination or Sanitation
? Hydrochloric Acid (with pH less than 7.2)
? Sodium Bisulphate Acid
? Generally Acidic Water (pH less than 7.2)
? Water pH greater than 7.6
7 Pump Sizing Guide
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7.1 A Word on Pump Sizing Choice
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The quick reference tables below outline conservative Australian Standard pump sizing recommendations.
There is a range of pump powers one can choose from. If thermal system efficiency is important then choose a pump
at the high end to produce high flow rate; take care not to over-pressurizing your system (see Optimizing Collector
Pressure below). If electrical efficiency (COP factor) is important to you then choose a pump near the lowest power
range. To help you understand the potential savings from such choices we have created an interactive pump sizing
simulator which can be found on our website at:
www.EcoOnline.com.au/oku-performance-pool-heating-pump-sizing
However, if you go with a lower power pump you’ll need the following:
? A slightly larger collector area; the pump sizing calculator will let you know by how much.
? You will need to check with the pump manufacture that your chosen pump can still prime reliably at your
pump height.
? We highly recommend you use a by-pass line to help your pump prime reliably, see Installing a By-Pass Tube
or By-Pass Ball Valve section below.
? Lastly you may need to run your main filter pump in the afternoon to help mix the warm water if your pool
volume turnover falls below the 50% - 75% range.
Australian Standard Input Pump Power for Independent Systems
Pool
Min - Max
For 1
st
Story Install (3m):
For 2
nd
Story Install (6m):
Please note the silicon joiners used in the system are not compatible with bromide
chlorination, hydrochloric acid use and/or acidic pool/spa water (pH less than 7.2). Sodium
Carbonate must be added to protect the system from acidic pH (<7). pH should be maintained
between 7.2-7.8 for maximum system longevity. If absolutely required Sodium Bisulphate acid
can be used to keep the pH down. Use of Hydrochloric Acid is permitted if the pH is kept
greater than 7.6.
Why? Acidic water with pH less than 7.0 has excess free H+ ions which like to bond to and
hence break apart silicon bonds.
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Water
Volume
Recommended
Flow
Min - Max
Input Pump Watts
Min - Max
Input Pump Watts
20,000 L
50 - 67 L/min
270 - 300 Watts
350 - 380 Watts
25,000 L
63 - 83 L/min
300 - 330 Watts
370 - 410 Watts
30,000 L
75 - 100 L/min
320 - 370 Watts
400 - 450 Watts
35,000 L
88 - 117 L/min
340 - 400 Watts
420 - 480 Watts
40,000 L
100 - 133 L/min
360 - 440 Watts
450 - 520 Watts
45,000 L
113 - 150 L/min
390 - 470 Watts
470 - 560 Watts
50,000 L
125 - 167 L/min
420 - 510 Watts
500 - 600 Watts
55,000 L
138 - 183 L/min
450 - 560 Watts
530 - 640 Watts
60,000 L
150 - 200 L/min
470 - 600 Watts
560 - 690 Watts
65,000 L
163 - 217 L/min
500 - 640 Watts
600 - 740 Watts
70,000 L
175 - 233 L/min
530 - 700 Watts
620 - 790 Watts
75,000 L
188 - 250 L/min
570 - 740 Watts
660 - 840 Watts
80,000 L
200 - 267 L/min
600 - 790 Watts
700 - 900 Watts
If you don’t know your pools water volume you can look it up from the table supplied below based on the total
water area and average depth:
7.2 Solar Pump Sizing for Booster Systems
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7.3 Filter Pump Sizing for Manual Systems
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Pool Water area vs Average Depth Conversion Table
Average depth
Waters Area
1.3 m
1.4 m
1.45 m
1.5 m
1.55 m
1.6 m
1.65 m
1.7 m
1.8 m
10 m
2
13000 L
14000 L
14500 L
15000 L
15500 L
16000 L
16500 L
17000 L
18000 L
15 m
2
19500 L
21000 L
21750 L
22500 L
23250 L
24000 L
24750 L
25500 L
27000 L
20 m
2
26000 L
28000 L
29000 L
30000 L
31000 L
32000 L
33000 L
34000 L
36000 L
25 m
2
32500 L
35000 L
36250 L
37500 L
38750 L
40000 L
41250 L
42500 L
45000L
30 m
2
39000 L
42000 L
43500 L
45000 L
46500 L
48000 L
49500 L
51000 L
54000 L
35 m
2
45500 L
49000 L
50750 L
52500 L
54250 L
56000 L
57750 L
59500 L
63000 L
40 m
2
52000 L
56000 L
58000 L
60000 L
62000 L
64000 L
66000 L
68000 L
72000 L
45 m
2
58500 L
63000 L
65250 L
67500 L
69750 L
72000 L
74250 L
76500 L
81000 L
50 m
2
65000 L
70000 L
72500 L
75000 L
77500 L
80000 L
82500 L
85000 L
90000 L
55 m
2
71500 L
77000 L
79750 L
82500 L
85250 L
88000 L
90750 L
93500 L
99000 L
For booster type systems you should choose a pump at or just below the minimum
specs in the table above. Why? The take off point for solar is already pressurized by the
filter pump, hence a smaller pump should be used.
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8 Solar Line PVC Pipe Sizing Guide
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The table below will help you choose the correct size PVC pipe for the solar lines running to and from your roof. On
the roof, we generally recommend 32mm, except for larger multiple row arrays with a secondary header pipe
feeding each row, for which you should use 40mm. Coming down the roof the pipe size can then be adapted to the
pipe size you have for your solar line ground run i.e. 40mm or 50mm.
Recommended PVC Piping Sizing for Solar Pool Heating System Lines
Anticipated Flow Rate
Absolute Minimum
Ideal PVC Pipe Size
Maximum Pipe Size
70 Litres/min
20mm
25mm
32mm
120 Litres/min
25mm
32mm
40mm
200 Litres/min
32mm
40mm
50mm
250 Litres/min
40mm
50mm
65mm
400 Litres/min
50mm
65mm
80mm
880 Litres/min
80mm
100mm
125mm
For manual type systems running off the main pool filter pump, please check that the
filter pump is large enough to accommodate the extra load of supplying water to the
collectors at the required pump height + a 1 meter pressure drop across the collector
array. Why? Filter pumps are geared for flow not pump height, solar pumps are geared
specifically for roof solar applications.
If the distance from the pool to the roof collector area is more than 10m we recommend
you use the next size up PVC pipe.
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9 Roof Type Compatibility Guide
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Roof Type
Peak to Valley Measure
Recommendation
Standard Corrugated Iron roof (Custom Orb)
17mm
Okay
Relatively Flat Tile roof
Less than 25mm
Okay
Spandek Iron roof
24mm
Okay
Modulated Tile roof
Greater than 25mm
Region A Only
Trimdek Iron roof
29mm
Region A Only
Klip-lok Iron roof
43mm
Region A Only
Flatdek Iron roof
45mm
Not Recommended
10 Wind and Climate Considerations
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If panels are to be installed on a roof then the following should be observed to limit wind
uplift potential.
1) Installed panels should lay flat close to the roofs surface. It is recommend the air
gap distance between the bottom of the installed collector and the valley points of
the roof corrugations should be no greater than approximately 40mm.
2) Panels should have adequate clearance from roof edges.
3) Panels on roofs MUST NOT be mounted on tilt frames.
Why? The average air gap distance between the mounted collector and roof structure has a
strong influence on wind loadings. Furthermore due to roof edge turbulence effects wind
loadings are highest near roof edges.
Panels installed above the roof structure with 50mm or greater underneath air gaps experience
much higher wind loadings and are now subject to the Australian wind loading standard
AS/NZD 1170.2.
It is the responsibility of the installer to consider wind loading factors, see “wind proofing”
section below. If the installation site is within strong wind speed areas then the extra
stainless steel guide line must be installed across each row with the in-between panel
anchor points. Do not assume supplied components are sufficient.
sufficient.
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11 Collector Array Components
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Interconnect OR Dual Header Panel Kit:
1 × HDPE dual header panel
1 × HDPE interconnect panel
2 × 40mm reinforced silicon joiners
4 × Stainless steel hose clamps
6 × 316 Stainless steel straps (black)
1 × 25cm length perforated 316 stainless band
1 × 40mm reinforced silicon joiner
1 × 25mm reinforced silicon joiner
4 × Stainless steel hose clamps
3 × 316 Stainless steel straps (black)
1 × 50cm length perforated 316 stainless band
Other Collector Array Components
1 × 32mm/40mm PVC Vacuum breaker valve
(MUST be installed)
2 × 40mm hose barb to 25mm/32mm
PVC glue socket/take off
Roof Mounting (Solar roof hook supplied only if requested and purchased)
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12 Additional Required Components (Not Supplied)
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You also require some of the following extra items depending on your system. These are available in any plumbing
store. The aluminium angle is available from Capral Ltd. or Ullrich Aluminium Pty. Ltd.
13 Required Tools
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- Battery powered hand drill
- Screwdriver
- Safety glasses
- Corking gun (for Silicon glue)
- Hack saw
- Gloves
- Personal Sun/UV protection
- Assorted drill bits
- Power Lead
- Heat Gun
- Tape measure
- Tin snips
- Industrial Ladder
- Needle nose pliers
- Power Lead
- A single 32mm (or 20mm) PVC Socket – for heat smoothing any misshapen barbs (see below)
1 × 304 Stainless solar roof hook (height adjustable)
Dimensions: A = 47.5mm,B = 112mm,C = 60mm
Aluminium angle 30mm x 30mm
x 4mm for metal roofs. 40mm x
40mm x 3mm for tile roofs
4mm stainless steel
cable & four cable ties
per row
PVC piping
(recommend 32mm
on roof)
PVC bits (including a 32mm
or 20mm PVC socket for
heat smoothing barbs)
We recommend AS 1477 compliant PVC piping with PN9 pressure rating or greater and
matching PVC fittings be used for all collector array plumbing.
When working with power or hand tools always follow the safety instructions. Wear the
recommended personal protective equipment, such as gloves, safety glasses, respiratory and
hearing projection. Make sure electrical cables are kept away from any water and from
foreign objects which pose a potential cable severing or crushing hazard. When using glues,
solvents or sealing agents make sure you know and seek the proper first aid in case of an
accident.
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14 Safety When Working at Heights
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The installer should always take the necessary safety precautions:
? Choose an appropriate day: cool, dry, calm and partly cloudy.
? Plan out your install: make sure you have all required components, tools and have plenty of allocated time.
? Only work at heights when you are well rested and alert.
? Never work alone, always work with at least one other person.
? Always use a safety harness or fall arrest system attached to appropriate roof anchor points.
? Wear clothes that fit well but that do not restrict movement.
? Use proper non-slip shoes.
? Use sunscreen.
14.1 Ladder Safety
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The chance of a falling from a ladder should never be
underestimated. Use only solid industrial grade ladders in good repair
that have been checked for faults.
Note: even a small unexpected movement of the ladder, such as a
small slip, can cause loss of balance and result in a fall.
The ladder should be placed on solid ground and should ALWAYS be
securely anchored at the base and secured at the top to prevent
slipping.
WHEN WORKING AT HEIGHTS - SAFETY COMES FIRST. A person can easily fall off a ladder or
roof and be seriously injured. For installations on a roof pitch greater than 22° and/or a double
story house we strongly recommend a highly competent professional installer install your solar
collector array. We strongly recommend the installer invests in roof safety guard rails and a
safety harness system, especially for DIY applications.
Solar panels should not be mounted in windy or gusty conditions; a panel can easily be caught
in the wind and cause a loss of balance and result in a fall.
The collectors can be walked on without damage. Take extreme care to use non-slip shoes and
never walk on wet collectors, especially on installations with any significant pitch. HDPE
material is a slippery and waxy surface. If the collectors need to be walked on for mounting
purposes, ALWAYS use a safety harness and fall arrest system.
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15 Choosing a Place to Install the Collector Array
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When choosing a location for your collector array you should consider:
? Shading - the collector array should receive no shading between the hours 10am to 4pm.
? Wind - the collector array should be mounted in a relatively sheltered location or with appropriate wind
proofing.
? Distant to pool/spa - collectors should be as close as possible to your pool (or spa).
? Direction - collectors should preferably face north for maximum heat collection; however the collector
array can also face any angle between East to West.
? Mounting elevation - this depends on the desired seasonal heat collection. Flatter elevations (< 45°) collect
more heat in the summer while installations closer to vertical (> 45°) produce more heat during
spring/autumn.
The figure to the left shows an example of a Child Safety
Barrier marked with a dashed line. A collector array should
not be mounted near the Child Safety Barrier - both on the
inside and outside of the Pool Area unless proper
clearances are observed. Consult your Local Government,
The Building Commission or SPASA for details regarding
pool safety barriers in your state. Please keep up to date
with regulations as they change over time. For more
information see, AUSTRALIAN STANDARDS 1926.1 2007
AND 1926.2 2007 FOR POOL SAFETY BARRIERS.
? Do not install the collectors leaning against the
outside of a Child Safety Barrier so as to create a climbable
object for children to access the pool or spa.
? Collectors installed inside the pool area in front of a
boundary fence must be offset away from the boundary
fence with the proper clearance from the top of the fence
so as not to provide a foothold for a child climbing into the
pool area.
? Do not install the collectors too close to the inside of a Child Safety Barrier so as to provide foot or
handholds from the outside of the barrier.
? For spa baths and above ground pools do not lean the collector array against the side of the spa or pool so as
to create a ramp or climbable object.
For ground mounted arrays, under no circumstances should a collector array be mounted in
anyway so as to compromise the effectiveness of a pool or spa Child Safety Barrier.
The collector array can face anywhere from West to East, with an optimal orientation of
North-west for most areas. South facing orientations are generally not recommended,
unless the roof pitch is quite flat < for southern states and < 15° for northern states.
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16 Collector Water Flow Configurations
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16.1 Dual Header Panel Single Row Flow Configuration
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16.2 Supply and Return Plumbing Options
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16.3 Dual Header Panel Two Rows In-Parallel Configuration
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16.4 Two Row Serpentine Flow Configuration
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Max:
100L/min
14 Panels
Max:
200L/min
28 Panels
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16.5 Parallel vs Serpentine Flow Configurations
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Parallel Configuration 17.3 (Recommended)
Serpentine 17.4 (Max: 100L/min, 20 Panels)
Splits flow - lower panel pressures
Higher panel pressures
Harder to plumb, more PVC bits
Easier to plumb but headers must be level
Better for larger panel per row arrays
Okay for arrays =10 per row
Okay for any pitch (flat) - 90° (fence)
Okay for standard roof pitches between to 35°
Use for three or more row configurations
Not suited for three row configurations
(unless array has = 20 panels)
16.6 Serpentine Flow for a Trapezoid or Parallelogram Array
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Max:
100L/min
~20 Panels
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16.7 Interconnect Panel Flow Configuration
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16.8 Three Row In-Parallel Flow Configuration
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Please note: the bottom row of panels in a three row (or more) configuration installed on a
roof pitch greater than 15° will experience greater pressures. When carrying out the
Pressure Optimization Procedure in Section 27, we recommend setting the lowest positive
pressure possible.
Max:
100L/min
~14 Panels
Max:
300L/min
~42 Panels
20° Pitch Roof
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16.9 Staggered Array Flow Configurations
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16.10 Level Ground Mounting Configurations
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For ground mounted arrays, under no circumstances should a collector array be mounted in
anyway so as to compromise the effectiveness of a pool or spa Child Safety Barrier.
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16.11 Split Array - Similar Level Configuration
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16.12 Split Array - Higher Level Configuration
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Split collector arrays should be installed facing the same direction - or have no more
than 30° compass facing difference between them. In this later case the temperature
sensor should be installed at an angle that is an average of the two collector array
compass facing directions.
Why? Depending on the location of the roof sensor the controller could turn the system
on with one bank of collectors in full shade.
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16.13 Return Line Configuration for Low Pitch Roof
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16.14 Preferred Bi-Directional Flow Configuration
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Collector arrays that face opposing compass directions are not recommended unless
the roof pitch is less than ~15°. In this case the temperature sensor should be installed
at an angle that is an average of the two collector array directions.
Why? Depending on the location of the roof sensor the controller could turn the system
on with one bank of collectors in full shade.
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16.15 Top Feed Flow Configuration for Non-Frost Areas
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16.16 Top Feed Flow Configuration for Frost Areas
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For frost prone areas the supply and return lines that runs over the top of the roof MUST
be run using UV rated “Spa Flex” hose (note Spa Flex hose requires special flexible PVC
glue).
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16.17 Plumbing Flow Configurations Not Recommended
To make sure all air bubbles are evacuated upon filling collector should be installed
with a minimum recommended pitch of 3-5°.
Ideally the collector array top header pipe should have a 1 to 2° upward slope toward
the outlet, to make sure all air is automatically removed from the entire array upon
filling. This is especially important for system with row containing 10 or more panels.
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17 Vacuum Release Location Options
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Generally, the longer the return line (between points A and D), the higher up the position of the vacuum release
needs to be. Preferably, the return line is kept short and the vacuum release positioned “off the roof” as this has the
advantage of protecting the roof and gutters from any corrosive water from vacuum release leaks. Collector
pressures can normally be set such that the stream reaches the top of the array (see Pressure Optimization below).
Return line length between point A and D
Recommended Vacuum Position
less than 3m
“off the roof”
between 3 - 5m
“bottom of array”
between 5 – 7m
“middle of array”
greater than 7m
“top of array”
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18 Collector Panel Plumbing Connections
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BEFORE CUTTING - put aside two collectors per row with undamaged
end caps. For all remaining collectors cut the single end cap off using a
sharp blade or hacksaw.
Check all collector pipe connections for raised edges or grooves on the
weld lines which could channel water and cause leaks. Clean these up
using a blade and/or a heat gun on a high setting.
Check all barb edges are smooth and spherical to seal properly. For any
high or low points, warm the barb edge with a heat gun on high at 450°C
for 3-4 seconds, then slide over a 32mm PVC socket (or 20mm socket for
the smaller interconnect barb) – this will knock down any high points.
When installing silicon joiners the hose clamp band should be at the end
of the silicon joiner and not on the connector barbs. HAND TIGHTEN ONLY
using with an 8mm hex socket. Do not glue in silicon joiners. (Pinhole
leaks can be sealed with a little silicon). You may need to slightly re-
tighten these with cool water running through the collectors at a later
stage, as HDPE has a high thermal contraction.
The barb end of inlet/outlet PVC adapter should be glued into the 40mm
silicon joiner with any neutral cure silicon as shown.
Why? PVC barbs can soften at extreme roof stagnation temperatures and
contract slightly with clamp pressure. HDPE, on the other hand, will not
soften significantly at the maximum roof stagnation temperature of ~80°C.
The non-barb end of inlet/outlet PVC adapter should be glued into 32mm
PVC sockets.
Note: some 32mm PVC socket brands are non-standard and are quite
loose with our adapters, if so apply a layer of PVC glue and let dry for 1
hour prior to final socket gluing or use a filler PVC glue.
Laceration hazard: Always cut away from your
body and ensure no parts of the body are in front
of the cutting blade.
Any misshapen barbs can be warmed to 150°C
with a heat gun to reform.
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18.1 PVC Pipe Roof Fixings
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19 Array Roof Fixing Configurations
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Note the high thermal contraction and natural relaxation of HDPE: Collectors will contact (in
length) by up to 10mm over time and 12mm thermally across temperature extremes. Hence
any fixing means must account for an ultimate contraction of 22mm in length per panel.
Key design principles when choosing a roof mounting means:
1) Consider the high thermal contraction of HDPE
2) Panels should be as low down on the roof as possible to prevent the wind from
catching the underside of panels
3) The stainless steel straps must allow for thermal movement of panels.
Note the large thermal movement in the array inlets and outlets (depending on how panels
you have in one row). PVC pipe work should NOT be fixed to the roof near the inlets and
outlets, but should be allowed to move with the collector array.
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19.1 Single or Multi-Row Metal Roof Fixings Wind Region A
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For row arrays exceeding 15 panels per row, expansion joiners MUST be used (contact
info@EcoOnline.com.au)
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19.2 Single or Multi-Row Metal Roof Fixings for Wind Regions B & C
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NOTE: For single or multi-row arrays in wind regions B or C, aluminium L-angle MUST be
installed for top and bottom of each row. Mid-panel attachments must also be installed.
For row arrays exceeding 15 panels per row, expansion joiners MUST be used (contact
info@EcoOnline.com.au)
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19.3 Single or Multi-Row Tile Roof Fixings for Wind Region A & B
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For single or multi-row arrays in wind regions B, aluminium L-angle MUST be run for the
top and bottom of each row.
For row arrays exceeding 15 panels per row, expansion joiners MUST be used (contact
info@EcoOnline.com.au)
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19.4 Low Wind Area Alternate Two Row Roof Fixings
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Allowed for Region A, Terrain 3 Wind Loadings ONLY
Installation of two rows between two aluminium angles will require twice the expansion gap in
the stainless steel straps. We also highly recommend you “season” the panels before
installation to removed some of the permanent contraction the panels are prone to.
“Seasoning” the panels involves laying the panels out in the sun for half a day on one
side, then flipping over for the other side.
For dual row array fixed between top and bottom array aluminium channels, do not exceed
10 panels per row. If you need to have more than 10 panels we recommend each row have
aluminium railings. Why? Panels strapped top and bottom to an aluminium railing will have
smaller side to side thermal movements.
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19.5 Application of the PVC Coated Stainless Steel Straps
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19.6 Three or More Row Roof Fixings
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Due to the large potential thermal contraction across three rows the strapping of three
or more rows of panels between one set of fixed top and bottom aluminium angles is not
recommended. Collector arrays consisting of three or more rows must have a pair of
aluminium L-angles top and bottom for each row of collectors or at least for each pair of
rows to allow for contraction.
IMPORTANT: DO NOT over tighten stainless
steel strapping. Strapping must have sufficient
play to allow for collector contraction. For the
installation of two rows between two
aluminium channels top and bottom strapping
should be loose enough to insert your little
finger between the strapping and the header
pipe. Why? Over-tightened straps can
experience tension and continual flexing of the
metal due to the thermal contraction of the
collectors. This can result in metal fatigue of
roof fixings over time.
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20 Tile Roof Aluminium Angle Mounting Options
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20.1 Top Panel Tile Attachment
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For tile roofs we recommend using a minimum roof hook spacing of 600mm in the top and
bottom row. Depending on your wind loading (see “Wind Proofing” section), angle of install
you may require a higher density of roof hooks and/or a stronger Aluminium L-angle, if unsure
please seek advice.
The collectors can be walked on without damage, however for tile roofs with solar roof hook
care should be taken not to step on or near a roof hook as you may crack a tile.
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20.2 Two Row Panel to Panel Attachment
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20.3 Two Row Mid Array Panel Attachment
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Region A, Terrain 3 Wind Loadings ONLY
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20.4 Bottom Panel Tile Attachment
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20.5 Stainless Steel Cable Anchor Point Option
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20.6 Perforated Band Under-Tile Anchor Point
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21 Corrugated Metal Roof Mounting Options
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21.1 Mounting Options for Top or Bottom Angle Rail
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For metal roofs we recommend using a minimum screw fixing space of 600mm when fixing
the aluminium angle. Depending on your wind loading (see “Wind Proofing” section), angle of
install, you may require a higher density of fixings and/or a stronger Aluminium angle, if
unsure please seek advice.
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21.2 Thermal Expansion Gaps for Aluminium Channels
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21.3 Metal Roof Screw Selection and Method
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22 Wind Proofing
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Note: roof installation of these panels in Wind Region D is not recommended. This section provides general advice
on wind loadings. If you have any doubt about your wind loadings please contact info@EcoOnline.com.au
22.1 Ultimate Peak Wind Loadings per Panel
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The following Tables specify the ultimate peak uplift any single panel can experience in a 1 in 500 year extreme
storm or cyclone event according to Australian Standard 1170.2 - 2011 (Amend 2 Dec 2012). These tables assume:
1) Panels are mounted on (touching) the roof structure - or no more than 20mm off the roof surface
2) Panels are situated away from a roof edge or corner
3) Installation is on a first story roof
4) Shortest side length of the building is more than twice the average building height (i.e. flat building)
If your installation falls outside of these assumptions please contact info@EcoOnline.com.au for alternative loadings.
Ultimate Peak Uplift Loadings Per Panel in Wind Region A (Kg)
Region A
< 10° Roof Pitch
12.5° Roof Pitch
15° Roof Pitch
17.5° Roof Pitch
> 20° Roof Pitch
Terrain
Category 1
120 Kg
110 Kg
95 Kg
90 Kg
80 Kg
Terrain
Category 2
100 Kg
90 Kg
80 Kg
70 Kg
65 Kg
Terrain
Category 2.5
90 Kg
80 Kg
70 Kg
65 Kg
60 Kg
Terrain
Category 3
85 Kg
75 Kg
65 Kg
60 Kg
55 Kg
Ultimate Peak Uplift Loadings Per Panel in Wind Region B (Kg)
Region B
< 10° Roof Pitch
12.5° Roof Pitch
15° Roof Pitch
17.5° Roof Pitch
> 20° Roof Pitch
Terrain
Category 1
195 Kg
175 Kg
150 Kg
140 Kg
130 Kg
Terrain
Category 2
160 Kg
145 Kg
125 Kg
115 Kg
105 Kg
Terrain
Category 2.5
150 Kg
130 Kg
115 Kg
105 Kg
100 Kg
Terrain
Category 3
135 Kg
120 Kg
105 Kg
95 Kg
90 Kg
Ultimate Peak Uplift Loadings Per Panel in Wind Region C (Kg)
Region C
< 10° Roof Pitch
12.5° Roof Pitch
15° Roof Pitch
17.5° Roof Pitch
> 20° Roof Pitch
Terrain
Category 1
290 Kg
255 Kg
225 Kg
210 Kg
190 Kg
Terrain
Category 2
240 Kg
215 Kg
185 Kg
170 Kg
160 Kg
Terrain
Category 2.5
220 Kg
195 Kg
170 Kg
155 Kg
145 Kg
Terrain
Category 3
200 Kg
175 Kg
155 Kg
145 Kg
130 Kg
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As an example if you are in Wind Region B and Terrain Category 3 and have a roof pitch 12.5° then any single panel
in your collector system could experience momentary peak uplifts of ~120Kg per panel. You should make sure your
panels and fixing components can withstand your relevant loadings. See below for Terrain Category definitions.
22.2 Terrain Category Definitions
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? Terrain Category 1: Open terrain few obstructions. Example flat, treeless, poorly grassed plains.
? Terrain Category 2: Open terrain with scattered obstructions having heights from 1 .5m to 5m, with at
least two building type obstructions per hectare. Example farmland and cleared subdivisions with
isolated trees.
? Terrain Category 2.5: Averaged intermediate between Terrain Category 2 and Terrain Category 3
? Terrain Category 3: Numerous closely spaced building obstructions having heights from 3m to 10m with
at least 10 house-size obstructions per hectare. For example a fully developed suburb or light industrial
estates.
22.3 Wind Region Definitions
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Coastal region boundaries are smooth lines set in from a smoothed coastline by 50km, 100km or 150km lines.
Note: Installations involving a second story roof or higher, or houses on hills, or panels
mounted 50mm or greater above the roof structure have higher potential wind loadings.
Please contact info@EcoOnline.com.au for ultimate wind loadings based on your details.
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22.4 Frequency of Extra Fixings for Different Regions
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For ultimate wind loadings
(see Tables above):
Extra Fixings Required
Less than 70Kg per panel
Stainless guide line is not required (but still recommended)
Greater than 70Kg per panel
Stainless guide line is required across each row
Greater than 120kg per panel
Stainless guide line is required with in-between anchor points
22.5 Roof Edge High Wind Loading Zones
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Note: Collector installations within a roof edge high wind loading zone will require 2 X the
fixing strength in that local area. Collector installations within a roof corner high wind loading
zone will require 3 X the fixing strength in that local area.
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23 Seasoning Panels and Minimizing Contraction Issues
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Please be aware, collectors will naturally age and contract by up to 10mm in length (and proportionally in width)
per panel in the first 1-4 years. Collectors will also thermally contract on a daily basis from a hot panel (80°) to a
cold panel (~0°) by up to 12mm in length (and proportionally in width) per panel. No special care need be taken for
single row array with 6 or less panels in one row as the straps supplied can accommodate these thermal changes, for
other arrays please follow the below procedures.
23.1 Mounting Procedure for Arrays 10 or Less Panels per Row
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We recommend you “Season” the panels by placing them in the hot sun for half a day on one side and half a day on
the other side to minimize any age contraction issues later. Then follow this mounting procedure:
Apply and tighten hose clamps and fixing straps to cool panels only (and/or with cool water
running at low pressures, see Pressure Optimization section below) and never hot panels.
Why? Applying straps/clamps to hot panels can cause issues for large arrays when the
collector array contracts significantly in the cool of the night and over time.
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23.2 Mounting Procedure for Arrays 15 or Less Panels per Row
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You MUST “Season” the panels by placing them in the hot sun for half a day on one side and half a day on the other
side to minimize any age contraction issues later. Then follow this mounting procedure:
Compact panels pipe to pipe, tighten clamps and apply fixing straps to cool panels only
(and/or with cool water running at low pressures, see Pressure Optimization section below),
and never hot panels. Why? Applying straps/clamps to hot panels can cause issues for large
arrays when the collector array contracts significantly in the cool of the night and over time.
For arrays containing 11-15 panels in a single row we strongly recommend aluminium
channels top and bottom for each row. Why? Panels strapped top and bottom to an
aluminium railing will have smaller side to side thermal movements.
For these arrays we recommend you locate the vacuum release off the roof and run the
system at a slight negative pressure. Why? A slight negative pressure will help reduce side to
side thermal movement, help compact panels during installation and guard against pool drain
events caused by a joiner pulling out.
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23.3 Mounting Arrays with 15 or More Panels per Row
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Please contact info@EcoOnline.com.au for special expansion joiners if you need to run your array with > (greater
than) 15 panels per row.
Arrays containing more than 16-20 panels in a row should only be installed with 25mm PVC
telescopic expansion couplings in the middle of the row to account for the thermal
movement. Arrays greater than 20 panels are allowed with extra expansion couplers;
however a 100L/min flow rate limitation per row applies.
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24 Plumbing Diagram Configurations
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24.1 Configuration 1: Manual/Timer/Motorized Valve System
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Configuration 1: Manual or motorized three-way valve (9). (Note: automatic controls are omitted for clarity).
Advantages:
Disadvantages:
* Manual system requires no extra pump required
* Manual system, needs to be turned off/on or on a
timer
* Only filtered water runs through collectors
* Large main filter pump needs to run all day for solar
* Can be retrofitted to pools that don’t have separate
solar provisions
* Motorized three-way valve and controller can be
retrofitted later
* Requires specialized motorized valve and controller to
automate
* Increases pressure and decreases flow rate in the filter
system
When installing PVC lines, attention should be given to the minimum spacing for pipe
supports and thermal expansion of long length of pipe work and the stress this produces
on joins. For complicated installations we recommend a professional installer install the
system, unless you are confident of the work to be performed.
For manual pool heating systems running off a main pool filter pump, please check that the
pump is large enough to accommodate the extra load of supplying water to the collectors
at the required pump height.
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24.2 Configuration 2: Booster/Retrofit System
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Configuration 2: Solar booster pump locked to run with filter pump - requires specific controller Dontek V7RTS.
Note: solar pump (13) should of lower flow than filter pump (4). A and B are the recommended temperature sensor
installation zones for the controller
Advantages:
Disadvantages:
* Less extra plumbing is required for solar
* Requires second pump and special controller
* Only filtered water runs through collectors
* Does not require separate solar suction provisions
* Large main filter pump + solar pump need to run all
day for solar
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24.3 Configuration 3: Independent/Separate System
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Configuration 3: Solar pump can run independently of the filter pump. A and B are the recommended temperature
sensor installation zones for the controller
Advantages:
Disadvantages:
* More energy efficient as a small solar pump runs
independent of the large main filter pump
* Requires separate solar suction provisions to be
installed
An inline mesh strainer (14) is recommended for this configuration; however the filter
basket on a pump is sufficient for OKU panels.
This system requires separate/independent Australian Standard approved suction and
return lines going into your pool. If you need to retro fit these you must contact a pool
builder.
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25 Installing the Controller for Independent Systems
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Please refer to the controller manual as different controllers have specific installation instructions. Here we only add
supplemental instructions; they should not override any specific controller instructions. Note: controller manuals are
downloadable from the EcoOnline website.
25.1 Installing the Roof/Hot Sensor
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If your controller comes with a long 20m cord hot roof sensor it should be adhered using silicon to a sun-exposed
roof tile (or section of corrugated metal for metal roofs) and NOT onto or into an OKU panel. Ideal placement is
within arm’s length of the gutter next or under to the panels.
25.2 Installing the Pool/Cold Sensor
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The cold sensor should be fitted inside a section of PVC suction line (before the solar pump) and sealed using the
grommet supplied. For this you will need to drill a hole in the suction line, please check the controller manual for the
recommended size.
25.3 Extending Sensor Cords
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The sensor cords can be extended using a similar type cord but in a larger gauge wire. Note, the Dontek cold sensor
uses a shielded type cord; hence you will need the same (but in a higher gauge) if extending it. Please contact
Dontek or Ascon if unsure.
PVC plastic should be preheated to 40°C using a heat gun or it may split when drilling.
You should practice on a pipe off cut as certain drill bit types can “bite” hard into PVC and
the drill can “kick”. We recommend a step drill bit. A cone shaped rolled up piece of
sandpaper can be used to even out or increase the diameter of the hole if you don’t have
the exact size drill bit.
When extending the cord we recommend a “lap splice” solder join with adhesive heat shrink.
Solder joins should not placed in any conduit section running under ground.
If the cord is too short the sensor can also be located on any unshaded “roof proxy”
surface that faces the same part of the sky as the panels to approximate the surface
temperature of the roof itself. Alternatively, it can be extended see below.
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26 Drain-Down, Frost Proofing and Winterization
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26.1 Drain Down
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All pool heating systems have a drain down design and MUST drain as fully as possible when the system stops.
26.2 Winterization
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Please note, while your potable HPDE/Silicon collector array does not require regular winter flushing, your solar
booster pump may require winter flushing. If this is the case and you do not want to run your system over winter
you can winterize your system by draining the solar side of the system, disconnecting the solar booster pump and
flushing the pump with clean water for storage over winter.
26.3 Installing a By-Pass Tube or By-Pass Ball Valve (18)
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A drain tube (or a by-pass ball valve with 6mm hole) can be used to drain non-self draining sections of PVC piping in
frost prone areas. In some cases where there are issues with pump priming and a perfectly sealing non-return valve
(8) is required; the aforementioned by-pass lines can be installed on the supply and return solar lines leading up to
the roof approximately one metre above pump level to reduce priming pressure. Please request this component if
you require it.
To install, drill into the PVC pipe using an 8.5mm drill. Note: PVC plastic should be
preheated to 40°C using a heat gun or it may split when drilling. Insert the rubber
grommet into the hole first, and then insert the single barb side barb into the
grommet. Finally, connect the by-pass tube to the double barb side barb ends.
The use of a water tight non-return valve on the solar supply will prevent drain down
which could result in water freezing inside PVC piping in frost prone areas and/or hot
water stagnation in summer. Any non-return valves installed on the supply line MUST
have a 6mm drain hole drilled in the flap to allow drain down. Why? The main purpose
of the non-return valve is to prevent a large volume of water from spinning the pumps
rotor backwards when the pump stops. A 6mm hole allows slow drain down while also
preventing hammer action in the flap when the pump stops.
PVC piping should be installed with a slope such that all water drains out of the piping to
when the pump stops to ensure a freeze proof system. There should be no U-bend water
traps - these can freeze over and burst plumbing lines in the winter. Note: PE lines are not
affected as these are frost impervious.
Independent systems with a drain tube anywhere in the
system MUST be installed with a fine (<0.5mm) strainer,
or else this tube may get blocked up.
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27 Optimizing Collector Pressure
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To make pressure adjustment depending on over-pressure or under-pressure, you’ll need to install either a ball by-
pass valve (18) to reduce pressure or a ball break valve (16) on the return line to increase back pressure (both at near
ground level for easy adjustment). Manual type systems need only the adjustable 3-way ball valve. Collector
pressures can then be adjusted as follow:
For recommendations on vacuum release locations and pressures for specific situations see section 17.
27.1 Air Bubble Issues in the Return Line
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Bubbling at the return outlet during initial start-up and air purge is normal. Constant bubbling after this initial startup
is not normal and signifies either an air leak on the pump suction line and/or negative pressure at the vacuum
release. To stop constant bubbling, check and fix any air leaks on the pump suction and follow the above Optimizing
Collector Pressure to get positive pressure at the vacuum release.
Do not expose the collector array to temporary pressures greater than 16 psi (110kPa).
Note: if for whatever reason water flow is fully blocked, a pump with a 15 meter head
pressure will generate 150kPa at ground level, 100kPa at 5m and 50kPa at 10m.
For vacuum release valves installed near the top of the collector array, stream heights greater
than 1m are in excessive in the long term and should be reduced to the recommend levels.
Why? Plastic longevity is strongly dependent on pressure fluctuations and temperatures.
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28 Checking for Balanced Water Flow
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At midday with the sun shining on the collectors and the pump running, run your hand over every part of each
collector in the array. The bottom face of each collector should be cool to the touch while the top of each collector
maybe slightly warmer to the touch. No part of any collector should be hot to the touch. Hot spots indicate that
there is no water flow through this part of the collector.
29 Service and Maintenance Schedule
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Maintenance Issue - Service Procedure
1
st
Month
1
st
Quarter
Annual
Checks
After
5
Years
Plastic Barbs Relaxing - All the stainless steel hose clamps may need
retightening as plastic relaxes overtime (hand tighten only).
X
X
Silicon Joiner Chemical Attack – Disconnect a single silicon joiner, dry
and check that the water exposed inside section has not turned grey or
become unfirm to the touch. This would indicate chemical attack from a
pH lower than 7. Replace as needed.
X
X
Stainless Strap Fatigue - Inspect all stainless steel fixing straps for wear
of PVC coating around the sharp Aluminium L-angle edge, which would
indicate fatigue working of straps. Replace as needed.
X
Mounting Frame - The integrity of the collector mounting frame and
windproofing components should be checked for any degradation.
Replace as needed.
X
Plumbing Degradation – Plumbing lines and fittings should be checked
for signs of UV and/or chemical damage. Replace as needed.
X
Vacuum Release Valve – The vacuum release valve (7) is a critical system
component. It should be checked that it is not weeping corrosive water
onto the roof.
X
Non-Return Valve – The non-return valve (8 see plumbing diagrams) is a
critical system component. It should be checked that the 6mm hole
drilled in the flap has not become blocked and that the collectors drain
fully when the pump stops.
X
Collector Plastic Contraction – Collectors can relax and contract by
10mm in length over the initial first few years. It should be checked that
the stainless steel straps or fixings have not become too tight as a result.
If required, straps will need to be loosened slightly. This check should be
carried out when the collectors are cool (water flowing).
X
During operation the outlet water flow should be strong with a temperature no greater
than about 1-2°C that of the inlet. Why? Faster flows rates will result in lower
temperature differences across the collector array and higher collector efficiencies;
however this should be balanced against electricity usage and maximum allowable panel
pressure.
Important: before carrying out any system maintenance you MUST check for any manual
and or technical service bulletin updates and download the latest installation manual
from our Downloads Page: www.EcoOnline.com.au/downloads
EcoOnline Performance+™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2019 Optex Solar Pty Ltd. All rights strictly reserved.
Page 50
Debris Accumulation on Roof – Check that there is no build up of debris
around pipework or collectors, and that water has a clear path to run
down.
X
Debris Accumulation in Collectors – Inspect the inner of the collectors.
Depending on conditions collectors may need to be flushed with a
suitable cleaning agent for debris accumulation after many years of use.
X
29.1 Collector Repair Procedure
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30 Important Installation Check List
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Your installation must have the following elements.
Correctly sized pump or pressure optimization carried out.
The top header pipe for any row was installed with a small slope toward the outlet, or at the least perfectly level.
Aluminium channel was laid top and bottom of each row or for a maximum of two rows.
The stainless steel strapping was installed with sufficient play to allow for collector contraction.
Ultimate uplift wind loadings were considered and panels secured appropriately.
A hot spot check was performed. All collectors are cool during full sun exposure (top of panels may be warmer).
Smooth flow is achieved; no air bubbling is present in pool after initial purging.
Frost proofing was considered. All collectors and PVC lines are sloped and arranged such that water runs back
into the pool at night.
A vacuum release valve MUST be installed on the roof on the return line.
A non-return valve was installed (with a small 6mm hole drilled in the flap).
Solar controller roof sensor was mounted on the roof and not on a solar collector.
User is aware of the maintenance schedule.

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