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PoolMasterproTM PVC Tube Solar Pool Heating System -- Installation and User Manual

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PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
EcoOnline PoolMaster
X2
10 Tube PVCn Strip Collector
Solar Pool Heating System
Installation and User Manual - Revised 24/11/2020
Optex Solar Pty. Ltd.
ABN: 88 128 228 884
www.EcoOnline.com.au
email: info@EcoOnline.com.au
© Copyright 2020 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.
PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 2
Contents Click Heading Titles to Navigate Up or Down
PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 4
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
‘HAZPAK’ produced by the work-cover authority
AS 3000 (2007) Sections 6.3, 6.4 & 6.5
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.
PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 5
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.
Due to the potential of falling from heights, mounting the solar strip collectors 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.
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.
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.
PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 6
3 Warranties
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EcoOnline™ offers the following Warranties
15 Year pro-rata Warranty on all strip 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 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
4.1 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:
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.
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 without a by-pass valve on a grossly oversized pump,
or with water pH less than 7.2,
or without the supplied strainer (for systems independent of the main filter),
or if the collectors are installed below the water level.
Why? Such installations will expose the collectors to debris build up, strong fatiguing
positive/negative pressures and/or chemical attack from hot water. These situations will
have detrimental effects on the collectors which will limit lifetimes.
PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 7
5 Pool Chemistry Compatibility Guide
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6 Pump Sizing Guide
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6.1 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.
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 to prime reliably, see Installing a By-Pass
Tube or By-Pass Ball Valve 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.
6.2 Quick Reference Solar Pump Sizing for Independent Systems
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The two tables below will give you the minimum and maximum Australian Standard pump power recommendations
for independent type systems in input watts (not output watts), these specs should be marked on the pump.
Minimum Recommended Pump Power is Limited by Water Turn-Over Requirements
Pool
Water Volume
Minimum
Recommended Flow
For 1
st
Story Install (3m):
Minimum Input Watts Required
For 2
nd
Story Install (6m):
Minimum Input Watts Required
20,000 L
50 L/min
270 Watts (0.36 HP)
350 Watts (0.47 HP)
25,000 L
63 L/min
290 Watts (0.39 HP)
370 Watts (0.50 HP)
30,000 L
75 L/min
320 Watts (0.42 HP)
400 Watts (0.53 HP)
35,000 L
88 L/min
340 Watts (0.46 HP)
420 Watts (0.56 HP)
40,000 L
100 L/min
370 Watts (0.49 HP)
450 Watts (0.60 HP)
45,000 L
113 L/min
390 Watts (0.52 HP)
470 Watts (0.63 HP)
50,000 L
125 L/min
420 Watts (0.56 HP)
500 Watts (0.67 HP)
55,000 L
138 L/min
450 Watts (0.60 HP)
530 Watts (0.71 HP)
60,000 L
150 L/min
470 Watts (0.64 HP)
560 Watts (0.75 HP)
65,000 L
163 L/min
500 Watts (0.68 HP)
590 Watts (0.79 HP)
70,000 L
175 L/min
530 Watts (0.72 HP)
620 Watts (0.83 HP)
This system is not compatible with 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.
Why? Acidic water with pH less than 7.0 has excess free H+ ions which like to bond to and
hence break apart polymer carbon and silicon bonds.
PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
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75,000 L
188 L/min
570 Watts (0.76 HP)
660 Watts (0.88 HP)
80,000 L
200 L/min
600 Watts (0.80 HP)
690 Watts (0.93 HP)
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:
Maximum Recommended Pump Power is Limited by Collector Pressure
Collectors
Gross Area
Maximum
Recommended Flow
For 1
st
Story Install (3m):
Maximum Input Watts
For 2
nd
Story Install (6m):
Maximum Input Watts
13 m
2
67 L/min
340 Watts (0.47 HP)
450 Watts (0.61 HP)
17 m
2
83 L/min
380 Watts (0.51 HP)
480 Watts (0.65 HP)
20 m
2
100 L/min
410 Watts (0.55 HP)
520 Watts (0.69 HP)
23 m
2
117 L/min
450 Watts (0.60 HP)
550 Watts (0.74 HP)
27 m
2
133 L/min
490 Watts (0.65 HP)
590 Watts (0.79 HP)
30 m
2
150 L/min
530 Watts (0.70 HP)
630 Watts (0.85 HP)
33 m
2
167 L/min
570 Watts (0.76 HP)
670 Watts (0.90 HP)
37 m
2
183 L/min
610 Watts (0.82 HP)
720 Watts (0.97 HP)
40 m
2
200 L/min
660 Watts (0.88 HP)
770 Watts (1.03 HP)
43 m
2
217 L/min
700 Watts (0.94 HP)
820 Watts (1.10 HP)
47 m
2
233 L/min
750 Watts (1.00 HP)
870 Watts (1.17 HP)
50 m
2
250 L/min
800 Watts (1.08 HP)
930 Watts (1.24 HP)
53 m
2
267 L/min
860 Watts (1.15HP)
980 Watts (1.32 HP)
6.3 Example Pump Sizing
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For example, for a large 75,000 Litre pool and 1st story roof your minimum Australian Standard pump specs from
the first table above are 566 Input Watts. If you want to install a 40 m
2
collector area for this pool for example, your
maximum pump specs, from the second table above are 656 Input Watts. Pumps well below the minimum specs
may not be strong enough to turn over a sufficient volume of water - while oversized pumps are more expensive to
run for little extra heat gain and may need a ball valve constriction installed depending on the collector’s internal
pressure.
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
45000 L
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
PoolMaster
X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 9
6.4 Solar Pump Sizing for Booster Systems
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6.5 Filter Pump Sizing for Manual Systems
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7 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 40 PVC (DN40) to match the manifolds. 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. 40 PVC (DN40) or 50 PVC (DN50).
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
20 PVC (DN20)
25 PVC (DN25)
32 PVC (DN30)
120 Litres/min
25 PVC (DN25)
32 PVC (DN30)
40 PVC (DN40)
200 Litres/min
32 PVC (DN30)
40 PVC (DN40)
50 PVC (DN50)
250 Litres/min
40 PVC (DN40)
50 PVC (DN50)
65 PVC (DN65)
400 Litres/min
50 PVC (DN50)
65 PVC (DN65)
80 PVC (DN80)
880 Litres/min
80 PVC (DN80)
100 PVC (DN100)
125 PVC (DN125)
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.
For manual type systems running off a 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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8 Collector Array Components
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1 × 4m
2
Strip Collector Kit (number of kits depends on system purchased)
1 × 27m 10 tube
PVC strip role
(150mm wide)
4 × 10 Tube Manifold
(150mm), 1 × Grommet,
2 × Cable ties
40 × tube
locking
collars
1 × silicon
tube
per 4m
2
kit
1 × Pipe clamp +
0.5m band for
fixing per 4m
2
kit
Other Essential System Components (depending on system purchased)
1 × 32/40 PVC
Vacuum breaker
valve
1 × Can of
silicon lubricant
spray
1 × Drain Down
Kit
2 × 10 locking
collar for
repair kit
1 × 10 joining
barb repair
kit
1 × In-line
pressure gauge
For Manual Systems (depending on purchase)
For Independent Systems (depending on purchase)
1 × 40 PVC (DN40) PVC 3-
way Ball valve
1 × 40 PVC (DN40) Spring
loaded non-return valve
1 × Dontek Controller
1 × 40 PVC (DN40) PVC
strainer
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X2
™ Solar Pool Heating System -- Installation & User Manual
© Copyright 2020 Optex Solar Pty Ltd. All rights strictly reserved.
Page 11
9 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 or
hardware store.
10 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
- Scissors
- Old cloth for silicon over spray
- Hammer
Appropriate PVC
piping
Various PVC
plumbing bits
P-type PVC
cement & primer
Fixing screws for
perforated band
We recommend AS 1477 compliant PVC piping with PN9 pressure rating or greater and
matching PVC fittings be used for all collector array plumbing.
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™ Solar Pool Heating System -- Installation & User Manual
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Page 12
11 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.
11.1 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.
12 Choosing a Place to Install the Collector Array
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When choosing a location for your collector array you should consider the following in order of importance:
Shading - the collector array should receive no shading between the hours 10am to 4pm.
Direction - collectors should preferably face north for maximum heat collection; however the collector
array can also face any angle between East to West.
Wind - the collector array should be mounted in a relatively sheltered location as much as possible.
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.
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.
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Page 13
13 Collector Water Flow Configurations
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13.1 Bottom Feed Basic (Square, Parallelogram or Trapezoid)
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The collector array can face anywhere from West to East, with an optimal orientation of
North 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.
All collector array configurations must be installed with a vacuum release valve on the
return line and a non-return valve on the pump side.
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13.2 Top Feed Basic (Square, Parallelogram or Trapezoid)
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13.3 Narrow Roof Space (Extra Manifolds) Configuration
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Array
Length
Manifold Count*
(per role)
Array Width**
(per role)
13.5 m
4 (supplied)
320 mm
9 m
6 (2 extra required)
480 mm
6.75 m
8 (4 extra required)
640 mm
5.4 m
10 (6 extra required)
800 mm
4.5 m
12 (8 extra required)
960 mm
3.86 m
14 (10 extra required)
1120 mm
3.375 m
16 (12 extra required)
1280 mm
* Manifold count must be an even number
** Includes the 150mm strip and 10mm gap
13.4 Trapezoid Narrow Roof Space (Extra Manifolds and Splice Kits)
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The extra manifold configuration is recommended over the multiple loops up and back
due to a more aesthetic appearance, however you will need to purchase extra pairs of
manifolds and extra joiner sets (if required).
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13.5 Bottom Feed Overlap (Square, Parallelogram or Trapezoid)
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As a general principle for all configurations, water flow in the manifold supply and return
pipe MUST always flow in the same direction to achieve balanced water flow in each
strip. Either up the roof for bottom feed system or down the roof for top feed systems.
Why? Without the third balance pipe water always takes the shortest path, reducing
flow in the higher tube strips.
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13.6 Top Feed Overlap (Square, Parallelogram or Trapezoid Layout)
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13.7 Bottom Feed Butterfly (for long 27m collector arrays)
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13.8 Top Feed Butterfly (for long 25m collector arrays)
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13.9 Multi-Directional Opposing Bottom and Top Feed Arrays
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13.10 Multi-Directional Arrays - Option 1
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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. Installations with a
purely south facing facet are still not recommended for southern areas of Australia.
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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13.11 Multi-Directional - Array Option 2
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Collector facets facing different compass directions should only be installed on flat roofs
with pitch no more than 30˚. In this case the temperature sensor should be installed
facing an angle that is an average of the two collector facet compass directions,
preferably weighted toward the compass direction of the larger area facet.
Why? Depending on the location of the roof sensor the controller could turn the system
on with one bank of collectors in full shade.
Collector facets facing different compass directions should only be installed on flat roofs
with pitch no more than 30˚. In this case the temperature sensor should be installed
facing an angle that is an average of the two collector facet compass directions,
preferably weighted toward the compass direction of the larger area facet.
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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13.12 Bottom Feed In-Parallel Split Arrays (For Multi-Level Split Arrays)
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13.13 Plumbing Configurations Not Recommend
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An “in parallel” configuration is recommended for installing two different arrays on any
differing or similar levels. For split flow multi-level arrays at substantially different
heights (>1m), a ball valve constriction MUST be installed to limit flow to the collector
array installed at the lower level.
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PoolMaster
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14 Roof Assembly and Attachment
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14.1 Tile Roof Mounting of Manifold Assembly
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When working with power or hand tools always follow the safety instructions. Wear the
recommended personal protective apparel. 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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14.2 Corrugated Metal Roof Mounting of Manifold Assembly
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14.3 Manifold and UV Shield Install Procedure
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Note the metal UV shield will have a different thermal expansion to the polymer PVC
pipe, hence observe the above points. This is so that the PVC pipe has thermal room to
move without placing shear stresses on the manifolds PVC barb.
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14.4 Connecting the Tubes to the Manifold Barbs
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14.5 Strip Collector Assembly and Gluing
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Take care not to overspray silicon on a critical part of the roof as this will create poor silicon
glue adhesion and a dangerous slippery working environment. Spray toward the manifold
assembly piping only - NOT toward the outgoing tubes. We recommend you use a cloth and
clean your hands regularly.
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Ensure roof is clean and dry. Any moss will need to be removed using a high pressure
stray. Use supplied silicone adhesive. If you run out, the brand “Parafix” outdoor silicon
can be used as an alternative and is available at most hardware stores.
When stripping the return leg, use a blunt flat head screwdriver to press holes through
weak point in one side of the webbing first. Use needle nose pliers to pull out webbing.
Consider the passage of water under the collector. Make sure water can still drain and
run under the collector. On very flat tile you will need to lay a vertical strip of spare
collector tube at periodic lengths to allow drainage under the collector strip.
When gluing the strip start from the manifold. Glue the first part then place a couple of
heavy objects such as a brick on an unglued part to stop the glued side of the strip from
being disturbed as you lift the next part of the strip to run silicon under. Move the bricks
along as you glue the next part.
If you make a mistake and you need to remove the locking collar use a hair dryer or heat
gun to warm the tube. For extra grip use a piece of sand paper around the tube to pull off.
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15 Extra Wind Proofing
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Coastal region boundaries are smooth lines set in from a smoothed coastline by 50km, 100km or 150km lines.
If you are in Wind Regions B, C or D, or situated on a hill or in open terrain, you will need to increase the above
specified frequency of fixings.
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15.1 Roof Edge Exclusions Zones
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Note: Strips installed near or within a roof edge exclusion zone require 2 X the fixing strength
in that local area. Strips installations within a roof corner exclusion zone require 3 X the fixing
strength in that local area.
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16 Collector Installation Order and Procedure
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1) Measure roof and plan out your installation using a diagram first.
2) Lay a few manifolds next to PVC pipe out on the ground, with the appropriate strip spacing and mark the
14.5mm holes to be drilled.
3) If your manifolds run at an angle or you are installing on tiles, you’ll need to check the tube strip spacing
pattern on the roof to get the correct manifold spacing.
4) Drill the first manifold holes and assemble the first few manifolds, checking spacing up on the roof as you go.
5) Lay the two completed manifold assemblies on the roof. In the appropriate place create the looped roof
attachment points for tiles, or perforated band diagonal supports for metal roofs.
6) Lay the manifold on the perforated band attachments and fix loosely at first using hose clamps.
7) Lay the collector strips out.
8) Cut the collector strips near the base of the respective barb manifold and connect the tubes to the barbs.
9) Glue remaining pipe work and vacuum release valve in place.
10) Tighten the hose clamps to secure the manifolds (while still allowing for some thermal expansion).
11) Drill 8.5mm hole and install pressure gauge on return line using grommet.
12) Allow 24 hours for the glue to set before pressurizing components.
13) Turn the system on for the first time and check for leaks.
14) Check pressure gauge you may need to reduce or increase pressure using PVC ball valves.
15) With the system running glue the collectors down (keep the system running/cool while the glue sets).
16) Install any remaining components.
Collectors laid on a flat surface can be walked on without damage. Do not step on a hot
collector with a roof fixing screw underneath it. Take extreme care to use non-slip shoes
and never walk on wet collectors, or just glued collectors.
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17 Plumbing Diagram Configurations
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17.1 Configuration 1: Independent/Separate System
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Notes: 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
When constructing pipe work consider the thermal expansion of long lengths of pipe work
and the stress this produces on joins. Note: the minimum spacing for PVC 40 pipe supports
is 900m, less for smaller pipes. Use the perforated band to create saddles.
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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17.2 Configuration 2: Integrated Independent System
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Notes: For pool with only 1 return port, the filter pump must be set on a timer to run outside of solar hours to
exclude the possibility of the two pumps running together. 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
* Can be retrofitted to older pools depending on access
to underground suction line
* Pumps can’t run simultaneously for pools with only 1
return port.
* Suction tees above or only just below the water line
will require regular maintenance of non-return valves
If the pool has more than one return port and the filter pump and solar pump run together,
the installer must check the combined flow does not exceed suction inlet flow rate limits.
checked.
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17.3 Notes on Teeing into the Suction Line for Configuration 2
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If the tee can’t be installed more than 1m below the waterline, or if it can only be installed above the waterline,
some installers will put in a perfectly sealing non-return on the solar line to stop the main filter pump de-priming.
Please be aware, this is a special valve with a polished ball and rubber seat, contact us at info@ecoonline.com.au if
you require it. A standard flap non-return will not suffice. Also note, such a system will need regular careful
maintenance of the solar and filter line non-returns. Any failures or even the smallest leaks in these non-returns, due
to twigs or grit getting into the rubber seal, will pass air and eventually de-prime pumps.
Note: the tee into the suction line must be performed far below the waterline (> 1m).
Why? When the filter pump starts it will create negative pressure in the suction line which
will drop the water line in the solar suction line - if the water line drops below the tee point
air will be drawn de-priming the main filter pump.
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17.4 Configuration 3: Manual/Timer/ Motorized Valve System
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Notes: 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
* Not recommended for two story installations
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. Generally, this configuration is not recommended for two
story or greater installs.
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17.5 Configuration 4: Booster/Retrofit System
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Notes: Solar booster pump locked to run with filter pump - requires specific controller Dontek V7RTS. 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
This configuration is not recommended for single story installs for pools with only a single
return port due to the potential over pressurization of the panels when both pumps run at
the same time. However for two story or greater installs, even with a single return port, this
is the recommended configuration for pools that don’t have separate suction ports.
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17.6 Installing the Strainer for Independent Systems
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Install the Tuffman strainer canister as shown in the plumbing diagram above
with the clear side down. If the strainer is installed below the waterline you
should install a PVC ball valve to isolate the strainer for cleaning purposes.
Depending on the level of pool use and debris in the pool the strainer may
need to be cleaned regularly. Use a jet of water.
18 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.com.au website.
18.1 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 roof. It should NOT be installed, on top off, inserted into, or under the
actual PVC collector strips. Ideal placement is within arm’s length of the gutter.
18.2 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.
PVC plastic should be preheated to 50˚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 “bight” 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.
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 collector strips to approximate the
surface temperature of the roof itself. Alternatively, it can be extended see below.
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18.3 Extending Sensor Cords
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The sensor cords can be extended using 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 type (but in a higher gauge) if extending it. Please contact
Dontek or Ascon if unsure.
19 Drain-Down, Frost Proofing and Winterization
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19.1 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.
19.2 Winterization
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Your collector strips as well as your solar booster pump will require regular winter flushing, you should make sure
the controller you have has a winter mode. If 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.
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.
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.
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19.3 Installing a By-Pass Tube or By-Pass Ball Valve
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A drain tube (18) or a by-pass ball valve (19) 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 50˚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.
20 Optimizing Collector Pressure
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20.1 Installing the Pressure Gauge
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The pressure gauge must be installed on the return line preferably near eye level. Drill
into the PVC pipe using an 8.5mm drill. Insert the rubber grommet into the hole
tapered end first. Use pink Teflon tape on brass tread, lubricate the brass barb with
silicon spray prior to insertion into the grommet. Note: PVC plastic should be
preheated to 50˚C using a heat gun or it may split when drilling.
20.2 Pressure Check Procedure
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To make pressure adjustment depending on over-pressure or under-pressure situations, you’ll need to install either
a ball by-pass valve (19) 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:
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Gauge Pressure
Pressure Adjustment Advice
Less than:
head pressure + 5 kPa
Install ball valve brake (16) (see plumbing diagrams) to
increase back pressure in return line
About equal to:
Head pressure + 5 kPa
Pressure is ideal no action required
Greater than:
head pressure + 5 kPa
Excessive pressure - install extra pool returns or remove
eyeballs from returns, or install by-pass (19) with ball valve
20.3 Negative Pressure and Air Bubble Issues
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If the pump height is substantial and/or you have more than one return outlet to your pool, it may be that your
pump cannot positive pressurize the vacuum release valve. In this case you will get undesirable constant bubbling in
the outlet to the pool as the vacuum release valve is at negative pressure and is drawing in air. If this happens you
will need to install the down draft/brake PVC ball valve (16) on the return line (see plumbing diagrams) and carry out
the following procedure:
Start the system and wait for it to settle.
1) Constrict flow in the return line using the ball valve brake (16, see plumbing diagrams) lever handle by a
small increment.
2) If after some time the air bubbling continues, constrict flow by another small increment.
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3) If air bubbles stop reliably at this point then the vacuum valve is now at the required positive pressure, the
pressure gauge should read a value near the head pressure (vertical distance from vacuum release and
pressure gauge) + a few kPa’s, this is ideal.
4) Leave the ball valve brake at this setting/constriction permanently (remove handle).
5) If the required constriction is greater than 50% you will need a stronger pump.
20.4 Adjusting the 3 Way Valve for Manual Systems
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The following procedure for a manual system need be carried out only once during installation.
1) Open the three way ball valve (9, see plumbing diagrams) using the lever handle by a small increment.
2) Wait to see if there is sufficient flow and back pressure to create positive pressure at the vacuum valve (7).
3) If after some time air bubbling is still present in the return line, open the three way valve (9 see plumbing
diagrams) by another small increment.
4) If air bubbles stop reliably at this point then the vacuum valve is now at the required positive pressure.
5) Fix in place a back stop on the ball valve lever handle at this travel point, as this will be your maximum
opening point for your three way valve when turning the heating system on again.
20.5 Optimizing Pressure for Oversized Pumps
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For an over-sized solar pump (13, see plumbing diagrams) we recommend the following procedure, carried out only
once during installation, to limit pressures inside the panels.
1) Removed any potential constrictions in the return line going back into the pool such as eyeballs in the return
outlets.
2) If pressure is still too great (as measured at the pressure gauge, see above Pressure Check Procedure, install
a by-pass ball valve (19) (see plumbing diagrams).
3) Turn the solar pump on with the by-pass-ball valve fully open.
4) Constrict the by-ball valve in small increments until you get the correct pressure, see above.
5) Fix the by-pass ball valve handle in place by some means.
Over-sized pumps and flow rates could potentially limit the lifetime of your collectors
due to pressure working. Note, the return line to the pool MUST be unconstricted, with
an appropriate number of pool outlets so as not to create significant back pressure.
Use the below procedure for solving air bubbling issues, DO NOT remove or drop the
level of the vacuum release valve or increase pump strength. The vacuum release valve
MUST be mounted as specified to ensure collectors are not pressure worked.
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21 Checking for Balanced Water Flow
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At midday with the sun shining on the collectors and the pump operational, run your hand over every part of each
collector in the array. The collector tube near the supply should be cool to the touch while the tubes near the return
should be only slightly warmer to the touch. No part of any collector should be hot to the touch. Hot spots indicate
that there is no or little water flow through this part of the tubes.
22 Service and Maintenance Schedule
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Maintenance Issue - Service Procedure
Monthly
Quarterly
Annually
Strainer – Depending on pool usage and level of debris you may
need to clean the strainer regularly.
X
Leaks – A leak check should be performed as leaks can corrode
metal roofs and gutters. Any leak should be repaired.
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
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
Plumbing Degradation – Plumbing should be checked for signs
of UV and/or chemical damage. Replace as needed.
X
Debris Accumulation – Check that there is no build up of debris
around pipe work or collectors, and that water has a clear path
to run down.
X
Winterizing System – You may need to prepare your system for
winter dormancy each year.
X
During operation the outlet water flow should be strong with a temperature no greater
than about 3-5°C that of the inlet. Why? Faster flows rates will result in a lower
temperature difference across the collector array and hence will maximize collector
efficiency; however this should be balanced against electricity usage and maximum
allowable tube 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
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22.1 Collector Puncture Repair Procedure
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Locate the leak, cut a 3mm cross section of tubing, strip webbing, and thread the
locking sleaves. Lubricate barb joiner using silicon spray. Join tubes using the barb
connector. Lubricate and slide on locking collar, using a blunt object, such as the
back of a kitchen spoon.
23 Important Installation Check List
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Your installation should have the following elements:
Correctly sized pump or pressure optimization carried out.
A third balance pipe must be installed for all collector arrays.
For independent systems not going through the filter, the supplied strainer MUST be installed.
The supplied vacuum release valve MUST be installed on the roof on the return line.
Smooth flow is achieved; no air bubbling is present in pool after initial purging.
A hot spot check was performed. All tube lengths are cool during full sun exposure, indicating water flow.
A non-return valve was installed (with a small 6mm hole drilled in the flap).
The drain/equalization tube was installed on the supply and return line.
Collectors should run and be adhered to the top of ridges of any roof structure, not the valleys to allow water
and debris drainage.
Frost proofing was considered. All PVC lines are sloped such that water runs back into the pool at night.
Solar controller roof sensor was mounted on the roof and not on a solar collector.
Extra silicon adhesive was used for collectors near roof exclusion zones (near roof edges).
Pipes and manifold assemblies are mounted above roof valleys to allow clear drainage of water and debris.
The pressure gauge was installed on return line and the pressure optimization procedure was carried out.
User is aware of the maintenance schedule.

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