Sundware Solar Pool System Installation Manual

Solar Pool Heating Systems

Installation Manual

Table of Content

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 Pipe and Pipe Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Cleaner and Cement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 Panels and Installation Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6 Solar Collector Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

7 Solar Pool Heating Systems Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8.1 Before You Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8.2 Array Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

8.3 Space Required For Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

8.4 Flow Rate through Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8.5 Control Module Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8.6 Pipe Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

8.7 Piping Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8.8 Layout of the Solar Panel Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8.9 Solar Panels.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8.10 Assemble the Solar Panel Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

8.11 Mounting the Solar Panel Array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8.12 Flat Roofs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

8.13 Ground Mounting Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

8.14 Plumbing the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

8.15 Plumbing Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

9 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

10 Pipe Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

11 Pipe Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

12 Control installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

12.1 Solar Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

12.2 TypicalAutomatic Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

12.3 System Check Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

12.4 TypicalAutomatic Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

12.5 Typical Control Operating (Les fonctions du ControleAutomatique) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

13 Special Roof Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

14 Operating and Check-Out Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

15 Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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1. Introduction

Before attempting installation, read the instructions in this manual carefully. This manual contains
easy to follow step-by-step procedures to property install our Techno-Solis pool solar system. Your
understanding our system and it parts will assure a successful, trouble-free installation. If you have
any product or installation questions regarding this installation, contact our representative at your
nearest area.

It is important to recognize that this manual outlines the recommended installation methods and
practices as prescribed by the factory. It is designed to aid the installer or even the novice through
providing optimum protection for the products. Also, these are the minimal requirements; addition­al protection may be required in hazardous environments or in areas subject to extremes of weather.
In those areas, the local expertise of the contractor may be relied upon in coordination with our ap­proval for special installation considerations.

Take time to read through this manual. It will guide you through the most e cient way to correctly
install our pool solar system. By following this step by step guide, your system will meet the instal­lation standards recommended by the factory. In addition, because we’ve included techniques and
tips gathered from experienced SUNDWARE contractors throughout the countries, using this instal­lation will save you time and e ort.

2. Getting Started

Before you begin your installation, here are a few important advices:

1. Caution- Safety Comes First !!!!

• There is no substitute for safety. Always exercise extreme caution, care and good jud
ments when working on or around a roof or pool area.

• Please take care to avoid hazards such as over-head electrical wires or loose shingles or
roof tiles.

• Be sure to secure ladders so they will not slip or fall.

• Do not allow extension cords to lie in the pool or in standing water.

• Wear shoes with proper tread to prevent slipping on the ladder or sloped roof areas.

• Disconnect all power to the pool equipment when installing an automatic control
system.

2. Before starting any work, determine the location of your system and prepare a schematic

drawing of the installation area. Include the location of the feed and return lines in this
drawing. Roof areas often times look bigger than they really are, so be sure to measure the
available area before making your schematic.

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3. The planned placement of the panels should allow the panels to drain when the pool pump

shuts o .

4. The paint of the outdoor pipes and  ttings should be UV resistant. Painted pipes and  ttings

will require additional maintenance.

5. Never walk on collectors when they are wet as they present a signi cant slip hazard. Walking

on the collectors should only take place when absolutely necessary.

6. Familiarize yourself with all of our pool solar components and plumbing materials that are

needed to complete the installation.

3. Pipe and Pipe Fittings

Use pressure rated Schedule 40 PVC pipe. You may prefer to use black, but because black PVC
can be di cult to  nd, some installers have inquired about the use of black ABS pipe instead. DO
NOT USE ABS PIPE. ABS pipe does not have the UV inhibitors that PVC pipe has, causing ABS pipe
to become brittle and to crack after several years of exposure.

Use PVC Schedule 40 pressure-rated fi ttings to match your PVC pipe. Be sure NOT TO USE
“plumbers” fi ttings or DWV fi ttings (drain, waste and vent).

4. Cleaner and Cement

Refer to the product’s label for selecting good quality Cleaner and CPVC all-purpose cement.
Before applying the cement, be sure to clean each fi tting and pipe end with the PVC Cleaner
or “primer.” Soon after cleaning each part, apply ample cement fi rst to the fi tting and then to the
pipe end. Insert the pipe end into the fi tting with a slight twisting motion until it seats to evenly
distribute the glue. Hold it in this position for 5 to 10 seconds to allow the joint to set up. Finally,
wipe excess cement off of the joint and pipe.

Note: Cold weather slows the set-up process for PVCglue. If installing in colder climates, refer to the
PVC glue manufacturer’s charts for curing times.

5. Panels and Installation Kits

Planning ahead and having the proper partsand kits for your system will make your installation
much easier. The kits and parts that are useful for our systems are shown here below under the
title “PARTS LIST ”.

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1. Necessary items:

A) SOLAR PANELS :

C15TS12 SOLAR PANEL 4’ x 12’
or C15TS10 SOLAR PANEL 4’ x 10’
or C15TS08 SOLAR PANEL 4’ x 8’

B) KITS :

K15 SYSSYSTEM KIT

(one per system) includes :
2 A15ADAPipe to panel adap. PVC 1 ½”x3” lg.
5 ALAGScrew ¼” x 2” lg. and washer
1 ARS-SILCaulking silicone
1 F20BSTRAP2”- black steel “U” support
2 K15BCAPEnd cap kit 1 ½”

K15 PANPANEL KIT

(one per system) includes :
2 A15HOSEPDM hose 1 ½”
4 AGC32Gear clamp #32
5 ALAGScrew ¼” x 2” lg. and washer
1 F20BSTRAP2”- black steel “U” support
½ ASTR29PPolyester strap roll (29 pi.)

K15PBWPIPING KIT PVC 1 1/2”

(one per system) includes :
1 AGC32Gear clamp #32
1 AGLUE1/2PT PVC glue #711
24 ALAGScrew ¼” x 2” lg. and washer
6 F15B901 1/2” PVC black 90° elbow
2 F15BCOU1 1/2” PVC black straight coupling
4 F15BSTRAP1 1/2” black steel “U” support
1 F15CORL/S1 1/2” PVC adaptor corlon/slip
10 F15W901 1/2” PVC white 90° elbow
1 F15WADA-M 1 1/2” PVC white male adapt.
4 F15WCOU1 1/2” PVC white straight coupling
8 F15WSTRAP 1 1/2” white steel “U” support
1 F15WTEE1 1/2” PVC white tee
40 P15B(ft.) 1 1/2” PVC black pipe
60 P15W(ft.) 1 1/2” PVC white pipe

C) CONTROLS

K15CTRMMANUAL CONTROL KIT

(one per system) includes :
1F15V21 1/2” PVC ball valve
1F15VCHECK 1 1/2” PVC check valve
1F15WTEE1 1/2” PVC white tee
1F15WU1 1/2” PVC white union

or

K15CTRAAUTO. CONTROL KIT

(one per system) includes :
4C-3MWire nuts
1C-FV2.03 way motorized valve PVC 2”
1C-HM4000HM4000 control box
1C-PSPool sensor #1S 1.0-10K
1C-RSRoof sensor #AS2-10K
10 C-TYETy-wrap 11” lg.
100 C-WIRE(ft.) Shielded wire #2-18
1F15VCHECK 1 1/2” PVC check valve
1F15WU1 1/2” PVC white union
3F20WRED152”x1 1/2” PVC red. bushing

2. Optional items :

K15BKBBANK KIT 1 1/2”

includes :
2A15ADAPipe to panel adap. PVC 1 ½”x3” lg.
5ALAGScrew ¼” x 2” lg. and washer
2F15B901 1/2” PVC black 90° elbow
1F20BSTRAP2”- black steel “U” support
2K15BCAPEnd cap kit 1 ½”

K15SPLBSPLIT KIT 1 1/2”

includes :
4A15ADAPipe to panel adap. PVC 1 ½”x3” lg.
2A15HOSEPDM hose 1 ½”
4AGC32Gear clamp #32
5ALAGScrew ¼” x 2” lg. and washer
4F15BCOU1 1/2” PVC black straight coupling
1F20BSTRAP2”- black steel “U” support

K15UNGUNDERGROUND KIT

includes :
4 AGC32Gear clamp #32
4 F15CORL/90C 1 1/2” PVC 90° elbow corlon/glued
4 F15CO1 1/2” DVW clean-out
4 F15WTEE1 1/2” PVC white tee

PARTS LIST

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6. Solar Collector Layout

The most common solar collector installations are shown below:

Note: No more than two (2) arrays are allowed in series feed and no more than eight (8) collec­tors are allowed in each array.

Fig (1): Single Row

Fig (2): Double Row

Fig (3): Single Row Spit Feed

Fig (4): Series Feed

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7. Solar Pool Heating Systems Components

Fig (5): Techno-Solis Solar Pool Heating System Components

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Installation Manual

The Solar pool system has the following components (see  gure 5)

1. The SUNDWARE PANELS are the key to your system. They absorb the sun’s heat e ciently

and transfer the energy to the swimming pool water that is pumped through them.

2. The SOLAR ROOF SENSOR* is installed beside the SUNDWARE solar panels to sense the

heat from the Sun. It relays the solar panel temperature to the automatic control.

3. The POOL WATER SENSOR* is installed in the pool plumbing, after the  lter. It senses the

pool water temperature and relays the information to the automatic control.

4. The AUTOMATIC CONTROL and MOTORIZED 3-WAY VALVE* compare the pool water tem-

perature to the solar roof temperature to turn the SUNDWARE solar heating system on or
o , as required.

5. The existing PUMP and FILTER circulate clean water to the pool and through the solar

panels when required.

6. The END CAPS seal the solar panel headers at the end of the row.

7. The LAG SCREWS and WASHERS are used to secure mounting straps to the roof.

8. The MOUNTING STRAPS are used with lag screw and washer to secure the solar panels to

the roof.

9. The EPDM HOSES connect the SUNDWARE solar panels together and connect the piping

to the solar panel array.

10. The CHECK VALVE* is used to prevent back ow circulation in the solar panels at night.

(1/8” diameter hole to be drilled in the  apper to allow for winter drainage).

11. The “U”STEEL SUPPORTS are used to anchor the top header of the solar panels.

* Only used in systems with automatic control.

Some systems will use a manual valve for turning the system on or o .

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8. Installation

8.1 Before You Start

Please read the complete manual before starting. If you have any installation problems or ques­tions, consult SUNDWARE GROUP’ distributor. Remember, serious damage may result from mal­function of the system and its components if instructions are not closely followed.

Check local plumbing, electrical and building codes. The installation must comply withthe local
regulations, which vary substantially from location to location.

8.2 Array Size

The number of solar panels required in the array is primary dependent upon the surface area of
the pool and the amount of solar energy available in the area of the installation.

The relationship between solar panel area and pool area should be: (for summer heating).

50% if solar panels are SOUTH facing

75% if solar panels are WEST facing

80% if solar panels are EAST facing

75% if solar panels are laid  at (with a minimum of 10 degrees inclination for properdrainage)

8.3 Space Required For Array

The minimum linear space for an array can be determined by the chart shown in  gure (6). Add
any length required to bypass roof obstructions.

The minimum vertical space required is equal to the length of the solar panel (8’, 10’ or 12’) plus
6” (150 mm) for the feed and return pipe runs above or below the array. Add a slope of 1 inch in
10 ft. (25mm per 3 meters) for the feed and return pipe runs to permit drainage.

Fig (6): Space Required for Solar Panel Arrays

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Quantity of Panels

“A”

in. m

3 12’-9” 3,89
4 17’-0” 5,18
5 21’-3” 6,5

6 25’-5” 7,77

7 29’-9” 9,06
8 34’-0” 10,36

9 38’-3” 11,65
10 42’-6” 12,95
11 46’-9” 14,24
12 51’-0” 15,54

8.4 Flow Rate through Array

The recommended  ow rate through the array is 3 to 10 GPM (11 to 35 liters) per panel. A  ow
rate of 5 GPM (18 liters) is recommended. The actual  ow rate is not that shown on the pool
pump because of pressure losses in the system. The actual  ow rate may be determined by using
an in-line  ow meter or calculated the time it takes to  ll a bucket of known capacity.

8.5 Control Module Location

Determine the location of the electronic control based on access to power, ease of cutting into
existing piping at the  lter outlet, and piping to and from the array. (Refer to the control manu­facturer’s instructions).

8.6 Pipe Size

Determine the length and size of the pipe required. Use only PVC pipe. Black ABS piping de­grades when exposed to sunlight. Use pipe cleaner before gluing with PVC glue. If connecting to
ABS piping, use PVC glue, not yellow ABS glue. Allow several hours for glue to set before turning
on pump.

For runs of less than 80 ft (25 meters), either feed or return, use 1 ½” pipe. For runs of more than
80 ft. (25 meters) a 2” pipe is recommended. Pipe runs should be planned so that the panels and
piping drain when the system is not active.

8.7 Piping Arrangement (Figure 7)

a. Always pipe the array reverse-return. End-feed end-return systems are not e cient.

b. If possible, install the return pipe at the top of the array; this will eliminate the air in the

system.

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