Optex Solar Eco Online Installation And User Manual

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 1

EcoOnline™

Solar Pool Heating System Manual

Installation and User Manual - Revised 25/11/2013

© Copyright 2012 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 tha n 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.

Optex Solar Pty. Ltd.

www.EcoOnline.com.au

email: info@EcoOnline.com.au

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 2

Contents

1 Key Terms .................................................................................................................................................................. 3

2 Pre-Installation Suitability & Safety Checklist ........................................................................................................... 4

3 Warranties ................................................................................................................................................................ 5

4 System Sizing Guarantee ........................................................................................................................................... 5

5 Collector Sizing Guide ............................................................................................................................................... 5

6 Pool Chemistry Compatibility Guide ......................................................................................................................... 6

7 Roof Type Compatibility Guide ................................................................................................................................. 6

8 Wind and Climate Considerations............................................................................................................................. 7

9 PVC Pipe and Pump Sizing Guide .............................................................................................................................. 7

10 Collector Array Components ..................................................................................................................................... 8

11 Additional Required Components (Not Supplied) .................................................................................................... 9

12 Required Tools ........................................................................................................................................................ 10

13 Safety When Working at Heights ............................................................................................................................ 11

14 Ladder Safety .......................................................................................................................................................... 11

15 Choosing a Place to Install the Collector Array ....................................................................................................... 12

16 Collector Array Configurations ................................................................................................................................ 13

17 Roof Attachment Options ....................................................................................................................................... 17

18 Collector Mounting Procedure ............................................................................................................................... 21

19 Collector Array Plumbing Connections ................................................................................................................... 22

20 Roof Fixing Configurations ...................................................................................................................................... 23

21 Wind Proofing ......................................................................................................................................................... 28

22 Plumbing ................................................................................................................................................................. 31

23 Frost Proofing and Winterization ............................................................................................................................ 34

24 Optimizing Collector Pressure ................................................................................................................................. 34

25 Checking for Balanced Water Flow through All Collectors ..................................................................................... 36

26 Service and Maintenance Schedule ........................................................................................................................ 36

27 Important Installation Check List ............................................................................................................................ 37

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 3

1 Key Terms

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 both manuals 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.

Indicates a SAFETY issue that may cause injury or property damage 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.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 4

2 Pre-Installation Suitability & Safety Checklist

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.

Due to the potential of falling from heights, mounting the solar panels on a roof or structure at heights should only be undertaken by a professional solar panel installer, unless you are accustomed to and confident of performing the work safely.

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.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 5

3 Warranties

EcoOnline™ offers the following Warranties

 5 year limited Warranty on all HDPE collectors  2 year Warranty on Reltech Pool Pumps  3 year Warranty on Davey Pool Pumps  2 Year Warranty on Dontek Controllers

See EcoOnline.com.au Terms and Conditions page for further details.

4 System Sizing Guarantee

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 systems 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

An interactive collector sizing calculator can be found on our website at,

http://www.EcoOnline.com.au/product-information/solar-pool-heating/sizing-guide

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 with a grossly oversized pump,  or in a manner that prevents collector from fully draining when the pump stops.

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 means.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 6

6 Pool Chemistry Compatibility Guide

Incompatible Chemistries

Alternatives Chemistry

✘ Bromide Based Chlorination

✔ Any other Chlorination or Sanitation

✘ Hydrochloric Acid

✔ Sodium Bisulphate Acid

✘ Acidic Water (pH less than 7.2)

✔ Water pH greater than 7.6

7 Roof Type Compatibility Guide

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

Not Recommended

Flatdek Iron roof

45mm

Not Recommended

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 touching the roof structure. 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 25mm.

2) Panels should have adequate clearance from roof edges.

3) Panels on roofs should 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.

This system is 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.

Why? Acidic water with pH (less than 7.0) has excess free H+ ions which like to bond to and hence break polymer carbon and silicon bonds.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 7

8 Wind and Climate Considerations

9 PVC Pipe and Pump Sizing Guide

We recommend that PVC pipe and the water flow rate for the solar pool heating system be sized according to the pools water volume. The table below will help you choose the correct size PVC pipe for the solar lines running to and from your roof.

Recommended PVC Pipe & Pump Sizing for Solar Pool/Spa Heating Systems

Your Pool/Spa

Size

Recommended

PVC Pipe Size

Flow Rate at Pump Height:

(Min – Max)

Pump Sizing:

(Single Story Install)

up to 2,500 L

20 mm

10 – 20 Litres/min

0.08 HP (60W solar)

up to 5,000 L

20 mm

15 – 30 Litres/min

0.08 HP (60W solar)

up to 11,000 L

25 mm

20 – 40 Litres/min

0.25 HP (200W)

up to 22,000 L

32 mm

40 – 80 Litres/min

0.3 HP (300W)

up to 37,000 L

40 mm

60 – 120 Litres/min

0.3 HP (400W)

up to 60,000 L

40 mm

100 – 200 Litres/min

0.5 HP (500W)

up to 77,000 L

50 mm

125 – 250 Litres/min

0.5 HP (600W)

up to 120,000 L

80 mm

200 – 400 Litres/min

1.0 HP (750W)

up to 260,000 L

100 mm

425 – 880 Litres/min

1.5 HP (1500W)

When installing a solar pool heating system, it is imperative to check whether the pump will provide the required water flow rate at the pump height of the installation.

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.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 8

10 Collector Array Components

Interconnect OR Dual Header Panel Kit:

1 × HDPE interconnect panel

1 × HDPE dual header panel

You should also check

that your pump does

not exceed the

maximum

recommended 3m/s

water flow velocity for

PVC piping. Check table to the right.

Maximum Recommended Flow Rates for PVC Pipe (3m/s)

PVC Pipe Size

Maximum Flow Rate

20 mm

70 Litres/min

25 mm

120 Litres/min

32 mm

200 Litres/min

40 mm

250 Litres/min

50 mm

400 Litres/min

80 mm

880 Litres/min

If you need to create solar inlet/outlet suction piping for your pool you should note that AS 3634-1989 recommends a maximum water velocity of 1.8m/s for this section of pipe. Please consult your pool builder.

Do not expose the collector array to 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.

Why? Plastic longevity is strongly dependent on pressure fluctuations and temperatures.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 9

11 Additional Required Components (Not Supplied)

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.

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

2 × 40mm reinforced silicon joiners

4 × Stainless steel hose clamps

6 × 316 Stainless steel straps (black)

1 × 25cm 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)

1 × 304 Stainless solar roof hook (height adjustable)

Dimensions: A = 47.5mm,B = 117.5mm,C = 60mm

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 10

12 Required Tools

- Battery powered hand drill with 8mm Hex socket - Screwdriver with 8mm socket fitting

- Silicon gun and clear silicon sealant - PVC pipe saw

- PVC glue - Level

- Teflon tape

- Industrial Ladder

30-32mm x 30-32mm x 3-

4mm Aluminium angle

4mm stainless steel cable & four cable ties per row

PVC 25-40mm (PN12)

piping

PVC 25-40mm PVC bits

We recommend AS 1477 compliant PVC 25-40mm piping with PN12 pressure rating or greater and matching PVC fittings be used for all collector array plumbing.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 11

13 Safety When Working at Heights

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 Ladder Safety

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. The installer MUST use an appropriate safety harness.

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.

Eco Online™ Solar Pool Heating System -- Installation Manual

Page 12

15 Choosing a Place to Install the Collector Array

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 northwest for maximum heat collection; however the collector

array can also face any angle between Northeast 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 North-east, with an optimal orientation of North-west for most areas. All other orientations are not recommended.

+ 25 hidden pages

Optex Solar Eco Online Installation And User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual