Optex Solar Eco Online Installation And User Manual

Eco Online™ Solar Pool Heating System -- Installation Manual

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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

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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

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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.

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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.

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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.

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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.

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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.

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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.

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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

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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.

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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.

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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.

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16 Collector Array Configurations

16.1 Dual Header Panel Array Configurations

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16.2 Interconnect Panel Array Configuration

16.3 Ground Mounted Collector Array Configuration

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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16.4 Split Collector Array - Similar Level Configuration

16.5 Split Collector Array - Higher Level Configuration

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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16.6 Recommended Return Line Configuration for Low Roof Pitch (2.5˚ - 5˚)

16.7 Bi-Directional Arrays

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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16.8 Plumbing Configurations Not Recommend

17 Roof Attachment Options

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 should not be used to support loads, only as security against

excessive wind speeds.

To make sure all air bubbles are evacuated upon filling collector MUST be installed with a minimum recommended pitch of 5˚.

Ideally the collector array top header pipe should have a 1 to 2° upward slope toward the outlet. This is to make sure all air is automatically removed from the entire array upon filling.

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17.1 Tile Roof Mounting Frame

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

and the dead weight of the collectors, you may require a higher density of roof hooks and/or a stronger Aluminium L-angle, if unsure please seek advice.

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17.2 Corrugated Metal Roof Mounting Frame

For metal 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 and the dead weight of the collectors, you may require a higher density of roof hooks and/or a stronger Aluminium L-angle, if unsure please seek advice.

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18 Collector Mounting Procedure

It is strongly recommended that the top straps be applied while cool pool/spa water is flowing through the panels.

Collectors will contact (in length) by up to 10mm over time and 12mm thermally for an ultimate contraction of 22mm in length per panel. For a two row array strapped between

a top and bottom aluminium rail the total ultimate contraction is then 44mm. The top and bottom strap must have sufficient play to account for this ultimate contraction.

The collectors can be walked on without damage. 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. Take extreme care to use non-slip shoes and never walk on wet collectors. HDPE material is slippery and

waxy. If the collectors need to be walked on for mounting purposes, ALWAYS use a safety harness and fall arrest system.

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19 Collector Array Plumbing Connections

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.

Check all collector pipe connections for raised edges or grooves on the weld lines which could channel water and cause leaks. Shave any edges or grooves flat with a blade being careful not to cut into the pipe.

After inserting silicon joiners and hose clamps moderately tighten the clamps using a hand screwdriver with an 8mm hex socket. Do not glue in silicon joiners as this allows for some collector contraction movement over time. If there is a pin hole leak, a small amount of silicon can be used to seal.

The inlet/outlet adapter PVC barbs should be glued into the silicon joiner with any neutral cure silicon. A flat spatula type surface should be used to push

silicon into the barbs indentations (as shown).

Why? PVC barbs can soften at extreme roof stagnation temperatures and contract sightly with clamps pressure. HDPE will not soften significantly at maximum roof stagnation temperatures.

Laceration hazard: Always cut away from your body and ensure no parts of the body are in front of the cutting blade. DO NOT perform this task when you are tired or in a rush. Plastic can be softened by heating.

Do not over tighten hose clamp at this stage - HDPE has a high thermal expansion. You’ll need to re-tighten these with cool water running through the collectors at a later stage. Make sure all nuts are accessible for future tightening.

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20 Roof Fixing Configurations

20.1 Application of the PVC Coated Stainless Steel Straps

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. 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.

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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20.2 Single Row Metal Roof Fixings

NOTE: For single or multi-row arrays in wind regions B or greater, aluminium L-angle MUST be run for the top and bottom of each row.

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20.3 Single Row Tile Roof Fixings

20.4 Perforated Band Under-Tile Anchor Point (For Region B or Multi-Row Arrays)

For single or multi-row arrays in wind regions B, aluminium L-angle MUST be run for the top and bottom of each row.

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20.5 Two Row Roof Fixings

20.6 Two Row Interconnect Panel Roof Fixings

Installation of two rows between two aluminium channels will require twice the expansion gap in the stainless steel straps.

NOTE: Installation of two rows between two aluminium channels will require twice the expansion gap in the stainless steel straps.

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20.7 Three or More Row Roof Fixings

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.

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21 Wind Proofing

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

21.1 Ultimate Peak Wind Loadings per Panel

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 that 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

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

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panels and fixing components can withstand your relevant loadings. See below for Terrain Category definitions.

21.2 Terrain Category Definitions

 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. Example fully developed suburb or light industrial estates.

21.3 Wind Region Definitions

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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21.4 Frequency of Extra Fixings for Different Regions

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

21.5 Roof Edge Exclusions Zones

Note: Collector installations within a roof edge exclusion zone require 2 X the fixing strength in that local area. Collector installations within a roof corner exclusion zone require 3 X the fixing strength in that local area.

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22 Plumbing

22.1 Configuration 1: Manual System

Advantages:

Disadvantages:

* No extra pump or motorized three way valve required

* Manual systems needs to be turned off/on

* Only filtered water runs through collectors

* Large main filter pump needs to be run for solar

* Requires specialized motorized valve and controller to

automate

* Increases pressure and decreases flow rate in the filter

system

Configuration 1: Manual or motorized three way valve (9). (Note: automatic controls are omitted for clarity).

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.

Collectors must be installed with a vacuum release valve on the return line and a non- return valve on the pump. Installations without these components will expose the collectors to strong negative internal pressures which could fatigue work, and/or result in significant shrinkage of the collectors which would put strain on roof attachments means.

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22.2 Configuration 2: Booster System

Advantages:

Disadvantages:

* Less extra plumbing is required for solar

* Requires second pump and special controller

* Only filtered water runs through collectors

* Large main filter pump need to be run for solar

Configuration 2: Solar booster pump locked to run with filter pump - requires specific controller.(Note solar pump 13

should of lower flow than filter pump 4).

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22.3 Configuration 3: Independent System

* Note A and B are the recommended temperature sensor installation zones for the Dontek controller

Advantages:

Disadvantages:

* Runs independent of the main filter pump

* Requires inline strainer

* Extra pipe work for solar may need to be run

Configuration 3: Solar booster pump can run independent of filter pump.

An inline mesh strainer (14) must be installed for this configuration.

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23 Frost Proofing and Winterization

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.

24 Optimizing Collector Pressure

Stream height

Collector Pressure

Pressure Adjustment Advice

No flow

Negative

Install ball valve brake (16 see plumbing diagrams) to

increase back pressure in return line

0.5 Meter

7.5 kPa

Pressure is ideal no action required

1 Meter

15 kPa

Pressure is still okay no action required

1.5 Meter

22.5 kPa

Borderline excessive pressure - install extra pool returns

or reduce pump power or install flow limiting ball valve

The use of a water tight non-return valve (8, see plumbing diagrams) will prevent drain down which could result in water freezing inside PVC piping in frost prone areas. Always use a non-water tight non-return valve in areas which can experience below zero freezing conditions.

Non-water tight non-return valves have a small (6mm) hole drilled in the non-return

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.

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24.1 Negative Pressure & Air Bubble Issues

If the pump height is substantial, it may be the case 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 drawing in air. If this happens you will need to install the PVC ball valve down draft brake (16, see plumbing diagrams) on the return line.

The following procedure need be carried out only once during installation. This procedure can be carried out with the vacuum valve’s top (and gasket removed).

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 air bubbling continues, constrict flow by another small increment.

3) If air bubbles stop reliably at this point then the vacuum breaker is now at the required positive pressure.

4) Leave the ball valve brake in place at this constriction permanently.

5) If the required constriction is greater than 50% you will need a stronger pump.

24.2 Adjusting the Three Way Valve for Manual Systems

The following procedure for manual system Configuration 1, need be carried out only once during installation. This procedure can be carried out with the vacuum valve’s top (and gasket removed).

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 release (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 breaker 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.

24.3 Optimizing Pressure for Oversized Pumps

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. This procedure can be carried out with the vacuum valve’s top (and gasket removed).

1) Removed any potential constrictions in the return line going back into the pool.

2) If pressure is still too great (as measured by the above “Pressure Optimization Test”) install a limiting ball

valve just above or below the non-return valve (8, see plumbing diagrams).

3) Turn the solar pump on with the limiting ball valve fully open.

Use the below procedure for solving air bubbling issues, DO NOT remove or drop the level of the vacuum release valve. The vacuum release valve MUST be mounted above the lowest point on the collector array on the roof to ensure collectors are not pressure worked.

Over-sized pumps and flow rates could potentially limit the lifetime of your OKU collectors due to pressure working of collectors. 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 in the panels.

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4) Constrict the ball valve in small increments until stream height is between 0.5m to 1m in height.

5) Replace vacuum valve’s top part and gasket.

6) If the required limiting ball valve constriction is too great we recommend a smaller pump.

25 Checking for Balanced Water Flow through All Collectors

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 bottom face of each collector should be cool to the touch while the top of each collector should be 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.

26 Service and Maintenance Schedule

Maintenance Issue - Service Procedure

1st

Month

Quarter

Annual

Checks

After

Years

Plastic Barbs Relaxing - All the stainless steel hose clamps may need

retightening as plastic relaxes overtime.

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 wind proofing 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.

Vacuum Release Valve – The vacuum release valve (7) is a critical system component. It should be checked that it is functioning correctly and that collectors drain fully when the pump stops. The collector face should never appear collapsed (concave) by negative pressure.

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.

During operation the outlet water flow should be strong with a temperature no greater than about 1-5°C that of the inlet. 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. A 3-5L/min/m2 flow is ideal.

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 www.EcoOnline.com.au/downloads

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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).

Debris Accumulation – 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.

26.1 Collector Puncture Repair Procedure

Drill out the puncture using a sharp drill bit (being careful not to drill into the opposite wall). Inject chlorine resistant pool silicon into the collector inner to create a ~10cm inner silicon disk plug. Wait one day before re-pressurizing.

27 Important Installation Check List

Your installation must have the following elements.

The top header pipe was installed with a 1 to 2° slope toward the outlet, or at the least perfectly level. Aluminium channel was laid top and bottom of each row or maximum 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 after initial purging. The pressure optimization procedure was carried out. Collectors and PVC plumbing lines were laid at such an angle so that all water drains from them. A fast opening 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).

Optex Solar Eco Online Installation And User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual