‘ eliocol INSTALLATION MANUAL fead: "these E yourself with the, are has heen taken to, "spent" ‘understanding | the’ system: and its parts will assure a successful, trouble-free installation. *AUTION SAFETY COMES FIRST i vlorklng 0 on of around your roof oF pool, please are 10 avold hazards such as electrical wires and/oose shingles. HELIOCOL® 19982 eliocol Notes:Hanocol INTRODUCTION WELCOME TO THE HELIOCOL FAMILY Holiocol Solar Poo! Panels are manufactured utilizing state of the art solartechnology and the most advanced production techniques, Heliocol collectors are sleek and simple, yet the patented over-molded design makes Heliocol durable enough to last a lifetime. However, a professional installation is very important to the overall success ofa system. Installed properly, a Heliocol Sysiemwillbe virtually maintenance {rae ast captures roe, abundant and reliable heat from the sun year after year. Whether you are 2 seasoned contractor or 4 homeowner instaling your own system, this manual will give you @ great deal of valuable information, Take time to read through this manual. It will guide you through the most elficient way to correctly instal a Heliocol 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 lips gathered trom experienced Hellocol contractors throughout the country, using this installation manual will o save you time and effort INSTALLATION MANUAL TABLE OF CONTENTS INTRODUCTION GETTING STARTED... PANELS & INSTALLATION KITS PARTS LIST ‘SOLAR PANEL LAYOUT AND HYDRAULICS... CONNECTING THE SOLAR PANELS TOGETHER MOUNTING THE SOLAR PANELS USING Z-BARS .. MOUNTING THE SOLAR PANELS ON A FLAT ROOP...... ASSEMBLY OF ROW SPACER KITS ie 7 15 CONNECTING THE SOLAR PANELS TO THE FEED AND RETURN LINES...... 16 NUNNING THE FEED AND RETURN LINES FHUM THE ROOF TO GROUND LEVEL wns 17 CONNECTING THE FEED AND RETURN LINES TO THE FILTRATION SYSTEM vesenssnnene 20 OPERATING & CHECK OUT PROCEDURES 22. ‘TROUBLESHOOTING 23. REPAIR PROCEDURES... rccscseesen 25 WARRANTY CLAIM PROCEDURES...Prenweus GETTING STARTED 7 Before you start your installation, here are a few important tips: 1) CAUTION - SAFETY COMES FIRST! Thereis no substilute for safely. Always exercise extreme caution, care, and goodjudgment when working on or around a roof or pool area. + Please take care to avoid hazards such as overhead electrical wires or loose shingles. + 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 when installing an automatic control system. 2) Always consult with the proper authorities or check with your local building department for the permit requirements and codes applicable before you start your job. 8) Before starting any work, determine the location of your system and prepare a schematic drawing of the installation area. Include the location of the fead and return lines in this drawing. Roof areas often times ‘ook bigger than they really are, so be sure to measure the available area before making your achematio, Be sure the planned placement of the panels will allow the panels to drain when the pool pump shuls olf 4) To insure a trouble-free system, don't take shortcuts. Whenever possible, panels should be installed so that they are accessible without being walked on, Walking on the collectors should only take place when absolutely necessary. 3 5) Familiarize yourself with all of the Heliocol components and plumbing materials thal you will need to complete the installation. Here is a list of the material most commonly used: ns, cannot Inces possible, If you have any installation questions, contact your Hellocol Representative for assistance. As the Installing contractor, you are responsible {for exercising good judgement when installing Hellocol Systems to protect the long term integrity of the Collectors as well as the mounting surfaces. PIPE Use pressure rated Schedule 40 PVC pipe. You may prefer to use black, as opposed to white, PVC pipe on {he roof for aesthetic reasons. Black PVC pipe is sometimes difficult to find and some people have inquired abou! the use of black ABS pipe instead. DO NOT USE ABS PIPE. ABS pipe doos nol have the UV inhibitors inal PVC pipe has so does not hold up inthe sun nearly as wellas PVC pipe, Alter several years of exposure it may become brittle and crack, PVC FINNINGS: nie PVC SCHEDULE 40 pressure rated fitings to match your PVC pipe. Be sure NOT TO USE “plumbers? {tings or DWV fittings (Drain, Waste and Vent). Black PVC filings are dificult to find. Some installors use Spray Paint to paint them black. Use @ high quality paint, preferably with UY inhibitors ifal al possible. Du not use inexpensive “discount store" brands, They will fade and pee! very quickly.he PVC CLEANER AND CEMENT Itis important to both CLEAN and CEMENT each PVC joint, Use a quality brand name product and refer to {he product's label for specific directions for use, Before applying cement, be sure fo clean each fiting and pipe end with the PVC Cleaner or primer’. Soon attercieaning each part, apply ample cement frstto th iting ang then to the pipe end. insert the pipe end into the fiting witha slight twisting motion until it seats 1o eveniy Gistnibute the glue. Hold tin this position for 5 to 10 seconds to allow the joint o sel-up. Finally, wipe excess cement off of joint and pipe, When gluing CPVC fittings to PVC pipe, such as the Heliocol {HC-117} Pipe Connector, it is necessary to use a good quality multi-purpose cement, MISCELLANEOUS Depending upon your specific job, you will need other plumbing items and materials such as: PVC valves, stainless stee! lag bolts, silicone caulk, silicone spray, galvanized pipe straps, black electrical wire ties, electrical wire nuts, 18a-22ga sensor wire, 14ga-16ga electrical wire with ground, tellon tape, conerete anchors and screws, electrical conduit, etc. Be sure to use qualily products that will withstand direct suntight year after year. TOOLS Planning ahead and having the proper tools and materials on the job will make your installation much easier. Typical tools and materials that are useful to have are: + Flat head and Philips head screwdriver * Channel lock pliers * Power drill wth bits, 5/16" and 7/16" sockets + Caulking gun + Pipe cutter or hacksaw + Ladderéliocal Panets & Instatcation Kirs HELIOCOL COMPONENTS ‘There are three Heliocol components to each system - The panels, panel kits and rowkits, For each Heliocol Panel that you install, you will ead aPANEL KIT. For each row (bank) of panels thal you instal, you will need either a ROW KIT or ADD-A-ROW KIT. To go around vents or pipes larger than 8", (chimneys, skylights or changes in roof elevations}, you will need 2 ROW SPACER KIT. Relerto the parts breakdown table on page 7 for more information regarding these kits. HC-PK: PANEL KIT One of these kits is required for each panel. It contains the parts necessary to connect the panels together and mount them on the installation surface. HC-RK: ROW KIT One of these kits is required for each row (bank) of panels when a VACUUM RELIEF VALVE is needed toinsure completedrain down whenthe system soll. [Atlease one of hese valvesis required by manufaclurer {o protect the system against internal freezing,] It contains the parts necessary to connect the panels to the feed and return lines. HC-ARK: ADD-A-ROW-KIT ‘One of these kits is required for each additfonal row (bank) of panels after the first row. It contains the parts neoessary to connect the panels to the PVC pipe between the rows. HC-RSK: ROW SPACER KIT One of these kits is required if you need to bypass a vent pipe, or obstacle larger than 6". Il also Is used to connect panels that are on different roof levels or thal are facing differant directions into one row. Itcontains the parts necessary to connect the panels ta the PVC pina hetween them. KIT CONTENTS PARTNO. DESCRIPTION (Hee? womK ciate’ HomsK HC-+05A VACUUM CAP WITH O-RING Bea 4 j HO-40s4 END CAP aa 2) Ho 108 SLED ‘| i HC-103 ALUMINUM Z-BAR, 30" | i HC-111 FLANGE (HEADER EXTENSION) 1 ee HC-113 PLASTIC PANEL CLAMP. 2 Bea (Top, Bottom, Latch & Gasket) i eo HC-1138 PLASTIC PANEL CLAMP, BOTTOM ONLY | i HO-117 PIPE CONNECTOR 2 Be 4 HC-1208 1/2" BRONZE CLDOW pe 1 HO-121 BRASS VACUUM RELIEF VALVE | 1 4 J HC4137 J-CLAMP : 4 1 OTHER INSTALLATION COMPONENTS REFERRED TO IN THIS MANUAL. He-125 VA"% 1 4/2" STAINLESS STEEL LAG BOLT Ho-128 1/4°X 2" STAINLESS STEEL LAG BOLT. HO-127 400 TAPCONS 1/4" 1-1/4" WITH DRILL BITHe leliocol Parts List phat Ho113T (TOP) wena gi \\ )) ara & )) Ho1136 (GASKET) HC-105A, He-106A Ho-117 HC188 (BOTTOM) pce END CAP PIPE CONNECTOR with O-RING Heats ieee ag} WES ¢ PANEL CLAMP te Mb se, HC-114 HC-129 HC-108. HC109 FLANGE O-RING FOR HC-1058 SLED ZBAR IRAQ Wg] Nas4g Vag ay “ o cE HC-120A HC-121 HC-135, HC-137 1/2" BRONZE ELBOW ‘VACUUM BREAKER G-CLAMP J-CLAMP: Wygaa aja co Ho-134 He-132 Ho-4194 ue REPAIR TOOL REPAIR PLUG REPAIR SLEEVE i NAgHS He-a344 He-1790 Hc-s210 THREE WAY VALVE UNION CHECK VALVE BALL VALVE2 SSS | le liocol SOLAR PANEL LAYOUT AND HYDRAULICS Shown bolow are the THRE! man i i int BREAKER ju TM) sneaker ol mln ti my l I i i Lh | i i i l (a : f i aly y ne ul TT JRETURN E ROW SPLITROOF ORIENTATION Ideally, collectors shouldbe located on a South facing or flat roof or on an elevated ground mounted rack facing South, The next bast orientation is West and finally East. A collector should never be installed on a North root without a reverse rack. CHOOSING THE RIGHT SIZE COLLECTOR ‘The roo! space available to you wil determine which model collector to use. Since Heliocol manufactures collectors in five different sizes, you have great flexibility in what you can design. The five panel sizes are: Model # Size HC105 Vx108) HO-12.5 Vx 12.5 HC-30 axe —Eego 2x05 HO-50 ax. Whenever possible, the largest panel (HC-50) should be used. This wil ‘+ reduce your total collector cost reduce labor and installation material cost reduce the length of the solar array reduce the number of roof penetrations produce a more attractive installation However, unique roof designs may require a combination of different size collectors lo best cover the roofarea. PANEL CONFIGURATIONS ‘There are many ways to configure a solar array. The most common and preferred is in one continuous row asin Fig. 4.1. There are, however, recommended limits fo the number of panels that can be installed this way to achieve even flaw throughout the array. The maximums are: Mouel # Maximum per row 2 12 HS, 40 HC-Bo" a These maximums can be exceeded i there is high flow or substantia! back pressure on the system which will force adequate low through every panel. When youhave more than the maximums, though, youshouldeither Use the Double Row layoutasin Fig. 42 orthe Single ow SpliFeediayoutasinFig. 8.3. Olcourse, the Double Row can also be used for smaller installations when space is a problem. PUMP HORSEPOWER The horsepower of your swimming poo! filration purnp must be adequale to supply the solar system with enough water to provide the recommended fiow rate necessary for the panels being installed. These recommended rates in gallons per minute (GPM) are: Model # Minimum Flow HC-10.5, 1GPM HC-12.5 apm HC-30 3GPM —HG:40 4GPM, Hea a For example; if you are installing Ten HC-49 panels, your pump must be able to deliver 40 GPM to the solar array. These flow rates may be exceeded by as much as 100% without any detrimental impact on the performance of the system. The existing poo! recircuialion pump is typically adequate for recirculating the water through the solar system. Generally, a { horsepower pump ie cufficiont fora ctandard pool selar system unless there is an unusually long pipe run, a high roof or a large number of panels. If you are not sure what your pump flow rate is, consull your Heliocol Representative or Pump Manulacturer for the pump's flaw characteristics.| - 2 I leliocol PLUMBING itis important that you use the proper size PVC pipe for the size of the solar array. Under sizing the pipe will pracluce tan miich restritinn ta the watar flow and unnecessatily reduce the flow rate to the panels. Use the following as a guide: Flow Rate Recommended pipe size 010 45 GPM 112" '46 to 80 GPM 2 For larger flow rates, consult your Hellocol Representative for the proper pipe size or allemative series plumbing techniques which will reduce the necessary flow rates on larger systems, Plumbing runs should be as short as possible and the “Hot Return" pipe should have the shoriest run to reduce potential heat loss in this pipe. Pipes should be supported with *C" clamps or*G" clamps a least every 4 feet topreventsagging, The"C" clamp usedoon pipe runs across 2 rool should be 1/2" largerthan the pipe diameter toallow forexpansion and contraction, The"C’ clamp usedon vertical orhorizontal runs on the side of abuilding should be the same size as the pipe dlameter to prevent vibration and to assure a protessional looking installation, Since 90 degree elbow fitings produce a high restriction to flow. you wlllwant to use as few as possible. Keep this inming when planning your plumbing runs. Thelc use cannot be avoided, but with careful forethought, you will use the least number possible. Occasionally, the use of two 45 degree fitings will eliminate a 90, but tis, nol necessary fo always use them as this wil run up the expense of your materials. BALANCED FLOW When you have to split a solar system as in Fig. 4.2 or Fig. 4., itis critical that the shown plumbing runs be followed to assure equal water flow through bath rows of panels. Since water wil follow the path of least resistance, ifone plumbing runs shorler that the other, more water will low through ilthan through the longer cone. Keep this in mind if you design a panel layout different than the examples. Your Heliocol Representalive can also assist with this and explain the use of “balancing valves" on larger systems. If you are installing the solar panels ona flat roof or flat ground rack, the top (return) header of the panel should beat least3" higher than the bottom (teed) header to assure equal flow through alof the tubes of al the panels, (see Fig. 9.1, Page 17). To achieve even distribution of water throughout the row of panels, proper flow rates and a lille back pressure should be present. AUTOMATIC DRAIN DOWN The panels and the PVC pipe should be installed so the water will drain out of hem when the pool pump shuts off. This is especially important in areas of the country where freezing conditions occur. (The Heliocol Solar Poo! Panels are warranted against intemal freezing when installed to allow for drain down.) H, as a result of unique roof design oradverse pool equipment cation, itis not possible to achieve complete automatic drain own, matival drain! down valves should be installed in eupropriate plaves in Ure plumbing or at tne end of he bottom (feed) header. Instead of installing an End Cap (HC-106A) at the end of the header you would place a Vac Cap {HC~105A) along with a Boiler Drain, These valves should be opened when shuiting down the system{orthe winter months orwhen freezing conditions are possible, Your Heliocol Representative canassist you with the parts necessary for manual drain down installations. 10u 9 leliocol CONNECTING THE SOLAR PANELS TOGETHER In subsequent pages of this installation manual, you will be instructed to connect Heliocol panels together by using the HC-113, plastic panel clamps. Itis helpful to familiarize yourself with this procedure ahead ol time. To assure a proper connection follow these steps: 1. Lay two panels next to one another with panel spacer bars on the botiom. Lay an HC-113 Plastic Patel Clann (op, Uulluin, gasket and latch at bath ends where the headers meet. (Tig 5.2 - A) 2. Clean the groove of both headers. 3. Spray the Panel Clamp Gasket with a slicone spray. (An easy way 10 do this is to put all of the ‘gaskets in one plastic bag. Spray silicone into the plastic bag to lubricate all of the Gaskets al once). 4, Insert gasket into the groove of ane of the headers. (Fig 5.2 - B) 5. Place ihe bottom halt (see Fig. 5.3) of the plastic panel clamp (HC-119) under the header end with the larger flat portion on the outside of the panel. (Fig 5.2 - C) 6. Seal both headers together by inserling the gasket inlo the opposite header groove and placing the ends of hath headers into the open space in the plastic panel clamp bottom. (Fig 5.2 - D) 7. Interlock the top half of the Plastic Panel Clamp with the tab on the bottom half. Swing top hail closed over top of headers. Lock both halves of the clamp togather using the Latch. (NOTE: Slide large end of Latch over small end of Plastic Panel Clamp assembly. (Fig 5.2 - E & F) 8. Use channel lock pliers to tighten the Latch grip by squeezing it with reasonable force until it seals flush or even siightly farther so it cannot slide out ofits position. (Fig 6.2 - G) 9. Repeat the procedure to connact the bottom headers of the panels, FIG 5.2 4Hetocoi MounTING THE SOLAR PANELS USING Z-BARS ‘The beauly of the “Z-Bar" installation method is its simplicity. It can be used on just about any type of roof or rack installation, Somot pn ar Tor 7 Ho-nNaL LATCH “ j= PANEL HEADER (TOP) HO-115G GASKET —— — Ho-s98 PANEL CLAMP BOTTOM Qe Hie-108 SLED mass T0108 2008 In order to install collectors properly using Z-Bars, follow these simple ctepa! 1) Attach PPC (Plastic Pane! Clamp) bottoms into Slads one side at atime as illustrated in FIG 7.1 Please note that the PPC hook is away from the Sled hook. (This may be done atthe lime of the. installation or in advance.) There are three PPC bottoms and two sleds per panel. 2) Snapa chalk line across the roof or rack where you want the Z-Bars to go. The collectors willhang from this Z-Bar. This chalk line should extend three and one quarter inches further than the ‘opposite end of the retuin side of the array and one inch above where the actual panel headers willbe located. Sinca the nanals shnuid slope slightly toward the feed end of the array for propor drainage, the chalk line should also slope this direction approximately 1" inch per 20 feet. 8) Position the first Z-Bar along the chalk tine opposite the retum end of the array and lag it to the rool. Lag the additional Z-bars to the roof along the chalk ine spaced 17° apart NOTE: The Z-Bar will extend 3 1/4" past each panel connection to allow for lateral expansion and connection. 4) Hook the two Slads with the attached PPC bottoms to the top of each 2-Bar 9 1/4* inches in on either side of the Z-bar. 5) Connect the top headers of the collectors together using the PPC hnttoms that are attached tothe Z-Bar and the PPC tops. 6) Attach bottom headers of the collectors with PPC’s, 7) Attach feed and return lines following Hellocol's published guidelines. 8) Be sure all four corners of the array are securely fastened to the roo! by either the Z-Bar or C- Clamps. (This is normally done on the feed and retum corners of the array by the C-Clamps used to support the weight of the plumbing. The top comer opposite the return should be already ‘supported by a Z-Bar and Sled, The bottom comer opposite the feed should to be supported by the U-Clamp supplied in the Row-Kit. Install the (HC-137) U-Clamp_3" inside the panel clamp along the header. Allow for a 1/2" gap between the U-Clamp and the bottom of the headlar (see figures 5.4 & 5.5) NOTE: Some Installers cut a 17" 2x4 spacer block to accurately measure the proper spacing between the Z-Bars, NOTE: Each panel kit contains two Sleds and three bottoms for supporting each panel every 2 feet. Additional Z-Rars, Sleds, and Panels Clamps will be nececeary on roofs with a pitch of 10/12 or greater. 12Ileltocol Upon completion of the installation you may want to bend the top corners of the Z-Bars down, This willeliminate the possibility of the Sled sliding off the Z-Bar due to lateral expansion & contraction. Nott NOTE: As the installing contractor, itis your job to evaluate any site specitic consitions that might creale unwanted roof wear. As an example, if you are installing the system on an inexpensive or soft asphall shingle roof, you'll want to put some 4" by 4" pads underneath each panel clamp along the bottom headers to prevent roof wear. Some installers make these pads from aluminum roof flashing or old mat systems, and altach them to the roof with silicone or an adhesive BOTTOM HALF PPC AND SLED thee panal camer suppon) COMPLETE PPC AND SLED (Placed at pe! connacone) Gorc CLAMP (To ssnpon get) Gorcclame {To stppot pumsieg) Fig 5.4 CLAM NOTE: Install the J-Clamp 3" inside the panel clamp on the corner opposite the feed line, The J-Clamp should also be 1/2" below the header to allow for expansion and contraction (See Figs, 5.4 & 5.5) NOTE: Each panel kit contains an extra (HC-108) Sled and an (HC-113B) Panel Clamp Bottom. These components are designed to provide added ‘support to the middle section of each collector. (See Fig. 5.6) 12" GAP \ \ FIG 5.5 13Henocoi IMouNTING THE SOLAR PANELS ON A FLAT ROOF Hyou have chosan a flat roof area to mount the eolar panele, it Ie recommended net to penetrate curface with a lag bolt FIBERGLASS COATED, METAL, OR SHINGLED FLAT ROOF Ityou have one of these three types of roofs with at least 3" of slope down the panel length, you can use the Z-Bar method previously described. Use liquid adhesive to secure the {HC-109} Z-Bar lo the rool, or use the “Free Floating method described below. BUILT-UP TAR AND GRAVEL ROOF ANN ROOFS WITH NO SLOPE I'you have this type roof, you can use the following installation mathod FLAT ROOF METHOD USING PRESSURE TREATED 4 x 4s Fetun Header Peale Comp ay A= Feeder Header ~. nl = BS (Gata FIG. 9.1 1. Some installers prefer to paint the pressure treated 4 x 4, but this is optional, 2, Place a 4.x 4 on the flat roof at the location of the return header (see Fig 9.1). Leave a 6" gap between each 8' section to allow water to drain through. if the roof Is truly flat, it Is not necessary 10 fasten this, assembly to the roof. The weight of the wood and the open tube design of the Heliocol panel will keep it frommoving inthe wind. Ifthe roofis slightly sloped, the use of liquid adhesive on the 4x4 is recommended 80 it doesn’t slide dawn the roof. 3, Asdescribed in the section on Z-Bar installations, fasten an HC-10 2-Bar every 17” across the top of the 4x4 using the (HC-125) 1/4" x1-1/2" Stainless Steel ag Rolts lag the Z-Bar loosely to the 4 x4 60 thal itcan tit own when the panelis connected tot. This creates a natural slope down lo the roo! and prevents the riser tubes from rubbing against the Z-Bar. 4. Mount the panes top header using the {HC-108) Sled as previously described. The rest of the panel will be free to rest on the root. 5. (Optional) If one of the plumbing lines runs next to the bottom header, you can loosely secure the bottom header to it using Biack nylon electrical ties. ‘6. Ifyou use a Row-Spacer-Kit with this assembly method, continue the 4 x 4 support under the pipe between panels to prevent sagging. Ifitis a long run, also clamp the pipe lo the 4 x 4, NOTE: Whenever unglazed solar collectors are installed on a rack ,a substrate should be mounted on the rack prior to mounting the panel. This eliminates heat loss and stress created by wind blowing on the back side of the rack. However, i this windis eliminated by other site specific, conditions, (i.e. windbreaks or fences) cubstrates are not necossarily required, NOTE: — There are all types of flat roof sufaces and as the installing contractor you are responsible for making sure that the installation will not damage the roof surface. If, for example, you havea very soft or rubberized roof surface, you'll want to protect the roof surface with some type of substrate, Alternatively, Heliocol panels are designed so that they can be installed with the spacer bars facing up or down. Youcan flip the panels over for installations on these types of roofs. 14Heticool ASSEMBLY OF ROW SPACER KITS When you need to install panels quar an ahsiniction larger than 6" wire or if the abstnuction is loss than one foot from a panel header, you'll need a row spacer kil to circumvent the obstruction HG 4 ye eve PIE FIG 8.1 HC-RSK 1. Connect the 4 {HC-117} Pipe Connectors to the headers of the collectors fo be connected with a [HC-113) Plastic Panel Clamp using the same procedures outlined in the section on connecting solar collectors together on page 12. 2, Cuttwolengths of 1-1/2" PVC pipe long enough tocement the (HC-117} Pipe Connectors on each collector to ach other 3. Cement the PVC pipe to the Pipe Connectors as shown in Fig. 8.1. 4, Ifthe distance between the collectors is over 4’, a 2° C-Clamp should be used on both pipes io prevent sagging, NOTE: When gluing the {HC-117) CPVC Pipe Connectors, it is necessary to use good quality multi- purpose cement, Flexible riser tubes are snapped out of the spacer bare to go around small obstructions. FIG 6.2 NOTE: Obstructions smallor than 6" can be circumvented by snapping the panoi riser tubes out of the spacer bar and spreading them around the obstruction (see Fig. 6.2). WARNING: THIS SHOULD NOT BE DONE BETWEEN THE HEADER AND THE FIRST SPACER BAR AS IT WILL POSSIBLY PULL THE RISER TUBE OUT OF THE HEADER. THE HELIOCOL WARRANTY DOES NOT COVER LEAKS OCCURRING FROM THIS TYPE OF INCORRECT INSTALLATION. A ROW SPACER KIT SHOULD HE USED FOR THIS SITU- ATION. 15lleltocol CONNECTING THE SOLAR PANELS TO THE FEED AND RETURN LINES eee Wepvesus a & eee QV GEE W4y37 — SS He.s0eAd Cap SS hays: fa weirs Sesto g oy Yiaesa cell Fe H-105A Vacuum Cap 1 hye3y FIG. 10.1 1. Connect an (HC-111} Flange to the top comer of the solar array, above the corner where the feed willbe, using the (HC-113) Plastic Panel Clamp as described in the section on connecting solar panels together on page 12. NOTE: The feed line willbe connected to the low end of the bottom header as previously determined when the chalk jine was snapped. The return line will be connected to the top header on the opposite ‘end of the array (see Figures on Page B}. 2. Wrap the smal threads of the {HC-1054} Vacuum Cap with teflon tape, Screw the Vacuum Cap into either end of the (HC-1208) Bronze Elbow. 3, Wrap the large threads of the (HC-105A} Vacuum Cap with teflon tape and serewit into the (HC-111} Flange located fon the top comer of the solar array. Be sure thal the [HC-128) O-Ring is in place on the Vaeuum Cap. 4. Wrap the threads of the (HC-121) Vacuum Breaker with tellon tape and screw i into the (HC-1208) Bronze Elbow. ‘The Vacuum Breaker should be straight up as in Fig, 10.2-A, 5. Attach the {HC-106A} End Cap on the bottom corner of the solar array opposite ol the corner where the feed line Is attached, using the (HC-113} Plastic Panel Clamp as dasoribed on page 12. (s0e Fig 10.2-8) 6. Allach the (HC-117) Pipe Connectors to the corners of the array where the feed and relum lines willbe, using the (HC-113} Plastic Panel Clamp as deserbbad on page 12. (e00 Fig, 10.2-C) 7. The (HO-117) Pipe Connector allows a 1%" PVG Pipe or a 114" PVC Ste, 2 to be glued direcly into the sockel. A 20° fitting should always be attached tothe return tina Pipe Connector to allow for lateral expansion and contraction of the return pipe run, 8. Connect the feed and return pipes using good plumbing techniques. He-129 Eta ‘Vacuum breaksr is Incalled on the top _Endeanisprapedlynwlalled Ate thatit CPVC Pipe Connestorieroaey toratiach header with an elbow, vacuurn cap, “O* ig mounted on the lower heador and wl men toelther the feed line (shown) or the "ing, lange, and panei clamp. ‘vert wal into the esrs felucn fine on the top header. Fic 10.2 16Ileliocol RUNNING THE FEED AND RETURN LINES FROM THE ROOF TO GROUND LEVEL Discussed here is the standard, most straight forward way of running the PVC pipe from the feed and return lines to the equipment pad. Some installations require a more crealive approach due lo unique roo! designs or ‘equipment pad locations. Whensvar possible, howevar, the return line should have the shortest run and all pipes should run slightly “downhil” to allow for automatic drain-down of the plumbing and solar array. AS discussed early i this is not possible, manual drain valves should be installed as needed, If your equipment pad is against your house, you may want to complete the necessary plumbing at the equip- ‘ment pad before completing this portion of the installation. This allows you to know exactly where the pipes should come down from the roof. If you will be trenching from the equipment pad to the installation location this is not necessary, 1. Cament the appropriate size PVG 20 degrae elbow to the retum line stub facing down toward the bottom header. Repent the process for the feed lina hander sth and! face the ellnw dawn away from the array (see Fig. 11.1, page 21). NOTE: Whenever cementing, lay a rag on the roof or rack under the joint to avoid dripping cement on the mounting surface. Also, it is a good idea to tape the cans of PVC cleaner and PVC Ce- ment together. They are less likely to tip over and spill this way. 2. Determine where the feed and return pipes will go over the edge of the roof. If possible, this should be perpendicular to the exact points where they will fasten into the existing system or into pipes coming trom fanutlier lovation (see Fig. 12.1, pg. 22). 3, Measure the distance from the return elbow down to the spot that you want to go, across the roaf, ta the point established above. Be sure to include the depth of the socket in the elbow in your measure- Ment. Cut a pieca af PVC pips to thie length. Flepest this process for the fead line. 4, Ifyou are not experienced at cutting and fitting pipe, itis a good idea to assemble al pipe and iitings before cementing them just in case you make an error, Clean the burrs off af these cut pipe lengths and insert them into the elbows. 5. Measure across the roof from these pipes to the points established in step 3, Cut and de-burr pipes 10 these lengths and assemble corner with 90 degree elbows. 6. Continue this process around the edge of the roof and down to the existing plumbing, keeping pipes as shor, straight and tight to the building as possible. 7. Once you are satisfied with the plumbing arrangement, go back and cement all joints together using the youu plumbing techniques explained In ihe "Geting Started” section, 8. Seoure iong pipe runs with C-clamps or G-clamps one size larger than the pipe diameter using (HC-125) 14" x 1-1/2" Stainless Stee! Lag Bolts and sificone caulk. Secure vertical pipe runs on the side of build- ings with C-clamps the same size as the pipe diameter using screws and anchors as needed NOTE: _Allfourcorners ofeach row of panels shouldbe securely fastenedto the roof. The corners should already be secured with the G-clamps or pipe straps on the plumbing lines connected to the feed andreturn ines. Thetop corner opposite the returncorner shuullalreay be secured by the pare! mounting hardware. Secure the bottom corner opposite the feed line with a J-clamp by placing it around the pane! header. (See figure 5.5, page 13) NOTE: Be sure to support all of the weight of the plumbing with G-clamps or pipe straps. The mounting hardware is not designed to support the weight of the plumbing in addition to the weight of the collectors, 17‘Vacuum Reliel_ Valve The above photo shows the feed line aitached to the The complated assembly shows the return line attached to bottom header and a vacuum breaker mounted othe top the lop header and an end cap an the bottom header. header. Photo 2 shows an assembled relur lin, FIG 11.1 18YOUR EXISTING POOL FILTRATION SYSTEM Eas TO SOLAR eee COLLECTOR FROM SOLAR (COOL) COLLECTOR (HoT) Ball Valve —3> (Ho-5210) \ Check Valve {HO-1790) Three Way Valve - NEW PLUMBING eee “EXISTING PLUMBING neck vane sp (HC-1780) t ca = Insiall after this point: * Chlorinator + Rater + Other poo! accessories (optionan FIG 12.1PIGHULUI CONNECTING THE FEED AND RETURN LINES TO THE FILTRATION SYSTEM Fig 12.1 on page 22 shows how a typical Heliocol Solar Pool Heating System is plumbed into existing pool plumbing. This drawing may not be just like every system you encounter. The feed and return plumbing on a solar system may be reversed, orit may have a different type of fiter, or may have addtional equipment such as a chlorinator, pool cleaner, gas healer, elc. I may also have a long run of plumbing from the pool equipment to the solar panels. Whether the system slike this ornot, Fig 12. wilhelp you understand the flow of water trom the pool, through the pump, filter, solar system and back to the pool. Study the diagram and become familiar with the valves needed to connect the solar panels to existing plumbing, Notice that the first (HC-1790} Union Check Valve is plumbed in after the fiter, This prevents the fiter from being backwashedby the water draining down trom the panels when the pump shutsoff. The (HC-3344) Three- Way Valve either diverts the waterto the solar system or directly back to he pool. This Three Way Valve should be a non-positive vaive. This enables the water in the solar system to drain back to the pool when the pump shuts off: The (HO-5210)Ball Valve uy Ue Sula! feed line allows you lo isulale (colnpletely shut off the solar system. The second (HC-1790} Union Check Valve on the solar return line prevents the water from flowing Up the retum line to the solar system when the solar system is shut of 1. Study the plumbing after the flterand decide where youare goingto installthe first [H0-1790} Union Check Valve and the PVC tee fitting (see Fig 12.1). If you have auxiliary equipment, you may need lo re-plumb: portion of your existing plumbing so this equipmentis located before oralterthe solarsystemas indicated InFig 12.1. NOTE: Use C-Clamps the same size as the outside diameter of your plumbing fittings to secure the pipe and fittings tightly to the wall. 2. Cutthe pipe after the filer where you have decided to locate the (HC-1790] Union Check Valve and where: your solar return pipe will attach to your existing pool retum line. if your pool plumbing is 1-1/2" and you are running 2" plumbing to your solar system, you should be using 2" valves and piping forall of your new plumbing, so you will need (2) 2°x1-1/2" reducer bushings to adapl your new 2" fitings fo the existing 1-1/2" pipe. 3. Asdiscussedearlierin this manual, itis a goodideatoassemble all pipe and fittings before cementing them justin case you make an error. Install an {HC-1790} Union Check Vaive on the pipe coming out ofthe filter. Be sure that the arrow showing tlow direction is pointed away from the filter. 4. The {HC-3344) Three-Way Valve will be installed next. It may come right next to the Check Valve, or you ‘may have to use some pipe and fittings to locate it off of the main ling, As slated earlier, use as few 90 dearee elbows as possible. 5. Install the {HC-5210} Ball Valve to the solar feed line and then connect the other side of the Ball Valve to one of the ports on the Three-Way Valve. 6. Install he second {HC-1790} Union Check Valve to the solar retum tine being sure thal the arrowis pointed away from the solar system and toward the pool, 7. Now determine where to locate the PVC Tes fitting. The Tee may bs located right noxt to the Three Way Valve or elsewhere depending on your system. Connect the Tee fing first to the solar return tine, then to the three-way valve, and then to the pool return line, 20Sera sees OC crmcemmeeee PSL —— Sl 8. Once youare satisfied with the plumbing arrangement, goback andcementtogetheralljoints that youhave nol already cemented. Use good plumbing techniques and rags fo protect the existing pool equipment NOTE: WHEN CEMENTING CHECK VALVES, TRY TO D0 SO IN A HORIZONTAL POSITION TO PREVENT CEMENT FROM DRIPPING INTO THE SPRING LOADED VALVE AND CEMENTING IT CLOSED! WHEN THIS IS NOT POSSIBLE, USE CEMENT SPARINGLY AND ALLOW IT TO. DRY SLIGHTLY BEFORE INSERTING THE PIPE INTO THE SOCKET. WHEN CEMENTING (WO AND THREE-WAY VALVES, EITHER REMOVE THE DIVERTER FROM THE VALVE OR CEMENT WITH THE DIVERTER TURNED AWAY FROM ANY OPEN PORT TO PREVENT THE CEMENT FROM RUNNING ONTO THE DIVERTER AND CEMENTING IT IN PLACE! ot uly professional looking installation, take tine to clean the white PVC pipe. Use a clean rag and pour ENC cleeneron itand then wipe the din and idenlltcation marks ofthe pipe. Do this onal exposed pipe. This 's also a good preparation i you plan on painting the pipe to match house color. IF YOU ARE INSTALLING AN AUTOMATIC SYSTEM Zhe basic difference between the manual system just oulined and an automatic system is the use of a a1OPERATING AND CHECK-OUT PROCEDURES CONGRATULATIONS: If you carefully followed the steps in this manual, you now have an ellicient, professional looking Heliocol Solar Pool Heating System. Before you run water through the system: Allow the cemented fitings adequate time to dry per manufacturer's directions. Verity that the check valves, control valves and vacuum breaker are installed properly. Verity that all Plastic Panel Clamp Clips are tight. Verity that all fag bolts are secure and that adequate silicone was used to prevent any roof leaks. Be sure all panel riser tubes are snapped into the spacer bars (excep! where they go around obstructions). '8e sure that panel riser tubes areNOT rubbing on the roof surface between spacerbars. Ifthey are, adjust spacer bars as needed to prevent this or a hole may develop in the riser tube. 5e certain that the system will automatically drain down when the pump is shut off or that enough manual drain valves have been included. 8, Verify that all pipe runs are properly supported with “C* clamps. TURNING THE SYSTEM ON ‘Turn the pool pump off. Turn the Three-Way Valve so the “closed” indicator points toward the pool side of the valve, Be sure that the Ball Valve on the {ead line is open, ‘Turn the poo! pump on. Setthe pool pump timer, ifused, so that the pump will un when sun is shining on the salerpanels, Usually 10:00 AM {o 4:00 PM, but this will vary with geographic location and time of year. When the solar system Is running, you should notice: * A slightly higher pressure reading on the pressure gauge. * At midday, if the sun is out, warmer water should he coming inta the pool. This water should be 3 - 5° warmer than the pool temperature. Use the back of your hari to better fee! the difference in water temperature. * Allthe panels should fee! cool to the touch when the sun is on them. (if they are not, soe ‘Troubleshooting section) 7. During the cooler months of the year itis essential that the paol surface be covered at night with @ “pool blanket” to maintain a comfortable water temperature, Low nighttime temperatures can lower tha water temperature more than the solar can recover during the day TURNING THE SYSTEM OFF 1. Turn the pool pump off. 2, Turn the Three-Way Valve so the ‘olosed! indicator points toward the solar side of the valve. 3._ Itisolating the panels, close the Ball Valve on the fead line after you are sure all the water has drained out of the panels and plumbing, + 4. Turn the poo! pump on to filter the pool as needed. so pene THAT'S ALL THERE IS TO IT. YOU HAVF INSTALLED & HELIOCOL SOLAR POOL HEATING BYETEM THAT HAS BEEN TESTED AND PROVEN WORLD-WIDE FOR QUALITY AND RELIABILITY. IF YOU RUN INTO ANY PROBLEMS WITH YOUR INSTALLATION OR HAVE ANY FUTURE PROBLEMS, CALL YOUR HELIOCOL REPRESENTATIVE OR OUR CORPORATE OFFICE AT (813) 572-6655. 22TROUBLESHOOTING PROBLEM CAUSE THERE ARE AIR BUBBLES — 1. There is not enough IN THE POOL ONLY water pressure in the WHEN THE SOLAR IS solar system to keep the OPERATING vacuum relief valve closed so its allowing air to be drawn into the water as it flows by the valve. 2. ifthe pump is making more noise, there may be air coming into the pump through an alr leak on the suction side of the pump due to the ump working harder tu move the water through, the solar system, ih the system lea shale towaray 23 a s lTeliocol SOLUTION Be sure filter is clean. Backwash to reduce pressure an older system, check for debris or scale in the mouth of the vacuum relief valve and clean if necessary. Move vacuum reliel vaive, bronze el- bowand vaccap to bottom header and pul solid end cap at end of top header ‘where vacuum reliel was located. Install an HC-5210 Ball Valve on the retum line to throltle the flow back to produce more back pressure on sys- tem. Eliminate the Vacuum Reliet Valve Increase pump horeopowor Be sure pump trap lid is on tight Check the "O" ring on the pump trap lid. Clean, lubricate or replace as needed. youhave a suction type poolcleaner, remove it. If this improves the air ‘bubbles, only useitwhen not operating the solar. Ityou havea clear id on the pump and can see air bubbles inthe trap, using a garden hose, run wateraverihelidand Bach joint individually to see if the air bubbies will clear up. If there is not a slear lid, listen lo pump noise for a smoother operation. Repair any air leaks. ‘Be sure filer Is clean, Backwash to Tedute pressure The pumpmaynotbe providing enough water fo the solar system. Check Water flow using a flow meter. In- tease pump horsepower ifneeded to fnaintain recommended flow. . “if there is a suction type cleaner in the ool, remove It. if this eliminates the problem,use it only when the solar system is oft IWthere is adequate flow, install an HG-210 Ball Valve on the retum line {0 throttle the flow back tu proauce "Mote back’ pressure on the system, This will even out the flow through the nel 1SEE PROBLEM SOME OF THE SOLAR PANELS AHE WARM TO THE TOUCH WHILE OTHERS ARE COOL TO THE TOUCH (Continued) THERE ARE LEAKS: : BETWEEN THE HEADERS | AT THE PLASTIC PANEL CLAMPS THERE IS A PIN HOLE LEAK IN ONE OF THE FISER TUBES THE WATER COMING FROMTHE SOLAR SYS- ‘TEM IS'NOT AS WAAM A THE THREE-WAY OR BALL VALVE WILL NOT TURN CAUSE 9. Ifthe system is a double row or a single row split feed array “PPC Latchis not light enoligh to seal the joint 2," PRC gasket is not seated squarely in “grooles 4. Hew installation, a ‘manutacturing defect 2. Risertubes rubbing on tool suriace 3. Birds or squirrels have damaged tubes while aller seeds or nuts, Internal parts need to be lubricated or replaced | | 9 leliocol SOLUTION b. Ifthe array contains more panels than the maxmumrecommendedon Page Sof thismanual, change the array toa double row or single raw split feed as shown in Fig 4.2 and 4.3 a. If there is adequate tlow, install an HC-5210 Ball Vaive on tha return side vl timeset uf panels that are ine coolest to throttle back the flow through these panels and force more through the warmer panels. b. If any section of the array contains morepanels thanthe maximum recor- mended on Page 9 of this manual, make changes as needed to correct this. " Side Latch farther across connection be- ‘tween top and bottom half of clamp. Disassemble PPC andverily that gasketis " seated propetiy. Contact aistnbutor for warranty repair into, Contact distributor for free repair kit and ‘adjust spacer bars to prevent fulure dam- age. Contact distributor for free repair kit and keep panels free of debris to praventfuture damage. Water flow through a single panel should "be less than 10 gallons perminule. Adjust _ the Three-Way Valve to by-pass some of water. Inthe cooler months of the year, the tom- ofailure nse through the panels may only +b622-3%, Use the backot yourhandto fee! the Water tompetature difference at the ‘Poolretumn inlet, It valve has a grease fiting, tum it clock wise to inject grease Into valve then turn thediverterpast the grease itting tospread the grease. Ifthe grease tting I ary, il with slicone grease. It thereis not afitting, disassemble Valve andlubricated with sil cone grease. Replace wom orbroken parts. ‘Consult the manual for the automatic sys- peinyouteierSS 2 _S>E>=—_——EEEEEE=— | leliocol Repair Procepures The Heliocol Solar Collector is a very durable product, but there are a few steps you should take to protect its longevity. * Try to avoid walking on the collectors. If you cannot avoid it, always wear soft-soled shoes. * Do not install Helioco! collectors in temperatures lower than 35 degrees. One of the big advantages of Helioco! Collectors is that if a panel should develop a leak, for whatever reason, it can most always be easily repaired in place. Here are the instructions for repairing @ leaking tube at the header. Channel lock pliers may be used in fieu of the repair clamp (HC-131), 1. Carefully cut off riser at the header with an X-Acto Knife, making sure not to cut adjacent tuhe 2. Cut 1/4" off end of riser tube. 3. Open repair clamp. 4. Place repair plug in hole in outer jaw of repair clamp, 5. Position repair clamp on top of collector header, so that repair plug Is centered on hole in header. 8. Tighten repair clamp so that the repair plug is forced into the header until the lip on the repair plug meets the header. 7. Open and remove the repair clamp. 8. Slide riser tube onto repair plug. 8. Repeat steps 1-8 for other end of riser tube. ‘These are the instructions for the repair of pin-hole leaks In riser tubes, ') Cut tne riser tube at the point of the leak. 2) Remove 1/4" of tubing 8) ‘Slide both ends of the riser tube into the provided EPDM sleeve. (HC-139) 4) Verify a water tight seal by turning on system 25HELIOCOL WARRANTY PROCEDURE AND INSTRUCTIONS As stated in the Warranty Certificate, HELIOCOL, USA, Inc, warrants ils solar collectors to be {ree from detects and workmanship in the manufacturing process under normal use and service for the duration ol the warranty period when purchased from an Authorized Dealer and properly installed. During thal lime, should 2 Heliocal collectorexhibit a defect, the defective collectorwillbe repaired or replaced withoul charge lorlabor by HELIOCOL, USA, Inc. or its authorized dealer or distributor. The Heliocel solar collector is probably one of the most trouble-free in the indusiry, and can take a lol of Wwoarand tear without damage. Care sluuld be taken, however, not fo abuse the produ, such as walking on the collectors, since there is a limit as to how much punishment any such plastic product can take. Foriunately, if a leak should occur in a Heliocol collector, it can most always be easily repaired in place bythe use of the Heliocol Repair Methods. Refer to the Heliocol Collector Repair Procedures sheet fordetails (on how to repaira collector and to the published updates in the Heliocol Herald. Any new solar installation shoud he tasted and ary leaks immediatoly repaired before leaving tin jobs Should the collector itself leak, which may have been caused by undue stress, this would be the ime lo repair i itpossible. Any repairs ofthis nature should take less than 10 minutes and should not involve a warraniy claim, since the labor cost involved would not justify the paperwork involved. ithe collector headers cracked, or ifthe collector cannot be successfully repaired at this pal, it should be replaced with another collector WARRANTY CLAIMS REPAIR OF COLLECTORS Try lo determine batore going out on a repair job whether itis a warranty problem or something else. if the problem |s one of a leaky collector, itcan most always be repaired in place. Ifa leak ocours a the header then the standard plug should be ullized. No more than 4 tubes should be repaired inthis fashion before replacing the panel. Pin-hole leaks along the riser tubes should be repaired utilizing the EPOM sleeve, Any Collector that has to be repaired under warranty more than twice should be replaced regardless of the nunuen Of eaks. Detailed repair instructions for each method are oullined on page 25, REPLACEMENT OF COLLECTORS Your Helioco! supplier will handle credit or exchange of detective collectors andor collectors that cannot be repaired after returned goods authorization (RGA) number hasbeen issued by HELIOCOLUSA, ING. The return for credit of collectors that can be repaired Is not authorized without prior special permission being grantedby! ICLIOCOL USA, INC. Toreceivean HGAnumercallHeliocol USA, Inc. at (407) 831-1941 between the hours of 8:00 am and 5:00 pm EST, BE SURE TO COMPLETE THE OWNER'S REGISTRATION FORM ON THE BOTTOM OF THE WARRANTY AND MAIL IT BACK TO HELIOCOL, USA TO REGISTER YOUR INSTALLATION. 26Heliocol [ | 27® elloco "Plug Into The Sun" (GRRE) eroiret saves! neczorexcosssins mrinum sioner Seestbiones (Be Solis endaeenen esate rosy ho eck o : An Environmentally Safe Produce is one chat helps tu preserve andl Protect our environment. The Helivcol Solar System does just that. An average pool in the United States, when heated hy a gas heater, will introduce into our ntmosphere 58 tons of CO} and 108 pounds of NOX over a ten-year period. A Heliceal Salar System that is cast effective, durable, ide into our air. Your Heliveuil systeu will and worry-free will intenuiuee io such healeh ha: provide you with natural, safe, and free energy year after year. REV. 298