DISCLAIMER. If you require a copy of the Rhino Black Warranty, please send an with a request to

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2 DISCLAIMER Please read and familiarise yourself with the instructions and component names outlined in this manual before attempting installation. If you have product or installation questions, please contact your local Rhino Solar representative. When working with heights or water, please remember to take all necessary safety precautions and avoid hazards, such as electrical wires, loose tiles/shingles. Relationship to Boss Product Warranty Whilst Boss Solars warranty is limited to covering the Rhino systems using Boss components, Boss acknowledges that there are a number of highly regarded SPHC/Installers whose installations do not strictly adhere to the recommendations and guidelines set out in this manual. This may be through the use of non- Boss components or alternative installation methods, adopted as a result of historical and/or geographical preference for their own time proven methods. On the proviso that Boss is satisfied that any system/components failure is not a direct result of any deviation from this manual, it is at Boss Solars discretion as to whether the warranty will be honoured. If you require a copy of the Rhino Black Warranty, please send an with a request to sales@bosssolar.com.au 1

3 TABLE OF CONTENTS Relationship to Boss Product Warranty... 1 TABLE OF CONTENTS... 2 RHINO SOLAR PARTS LIST... 3 BEFORE YOU START... 4 Required Tools... 4 THINGS TO REMEMBER... 5 Calculating how much Collector is required... 5 Calculating the Surface Area of a Rectangular or Square Pool... 5 Calculating the Surface Area of an Oddly Shaped Pool... 6 Calculating the Amount of Collector Required... 6 Solar Collector Layouts and Balanced Flow... 6 Balanced Flow... 7 Rhino Solar Panel Sizes... 8 Extend Any Panel Length... 9 Plumbing Considerations Automatic Drain Down HOW TO INSTALL RHINO SOLAR Appendix 1: Marking the location of the Roof Mounts Appendix 2: Installing the Roof Mounts on Metal Roofs Appendix 3: Installing the Top Roof Mounts on Tiled Roofs Appendix 4: How to Assemble the Collector Appendix 5: Installing Rhino Solar Around Obstacles Rhino Manifold Plugs PVC Pipes Appendix 6: How to Connect the Solar Panels Together (Installing the Clamp Ring Assembly) Appendix 7: Connecting the Panel System to the Supply and Return Lines Appendix 8: Installing the End Caps Appendix 9: Connecting the Supply and Return Lines from the Roof to Ground Level Appendix 10: Connecting the Panels to the Existing Pool Filtration System Separate Circuit Configuration Appendix 11: How to Install the Drain Tube Appendix 12: How to Install the TufFilta Appendix 13: Operating and Check out Procedures Appendix 14: Pressure Testing the System Appendix 15: Troubleshooting Appendix 16: Maintenance Schedule

4 RHINO SOLAR PARTS LIST Rhino Collector (3 sizes available) Header Pipe (5 sizes available) Barb Lock Roof Mount Assembly Clamp Ring Assembly Fixing Track (5 sizes available) Fixing Clip End Cap Manifold Plugs Connector Block (Panel Extender) Slide Track Aluminium Extrusion (300mm Long) Rubber Roof Pad (100mm Long) Tiled Roof Bracket Assembly Replacement Silicone Barb Seal PVC Coupling Charcoal TufGauge - Pressure Gauge TufFilta - Inline Solar Filter VacRel Vacuum Relief Valve Drain Tube 3

5 BEFORE YOU START Ensure you have taken all necessary safety precautions before beginning As the installer, you are responsible for exercising good judgment when installing Rhino Solar to protect the long term integrity of the collectors as well as the mounting surface(s) Check the code and permit requirements for your area with your local building department Familiarise yourself with all of the Rhino Solar components and plumbing materials required to complete the installation To ensure that you don t break any roof tiles, try to walk on the crease of the tile, not the middle. If you break a tile you should replace it. On tin roofs, walk on the screw/nail line. Walking elsewhere may cause the roof to crease. For safety reasons, avoid standing or walking on the Rhino Solar panels whenever possible, whilst they can take your weight, panels have less grip when compared to normal roof surfaces, particularly when wet. Ideally, panels should be installed with sufficient room to be accessed without being walked on. A Schematic Drawing should be prepared before starting any work. Ensure you have accurately measured the available roof space and marked any roof protrusions. This will allow you to determine the appropriate location and orientations of your system. Depending upon your installation, additional plumbing materials and items may be required. When selecting additional material please ensure you select: o Quality products that are able to withstand long term direct UV exposure o 40mm pressure rated PVC pipes and fittings o Use good quality multi-purpose PVC Cleaners and Cement Do not use ABS, plumber s fittings, DWV fittings (drain, waste, and vent) or a lower standard substitute. It is important to remember that no two installations are exactly alike. However, most standard installations do share similarities. Required Tools Before beginning the installation, it is a good idea to check that you have all of the necessary tools and materials on hand. Below is a list of the typical tools and materials that are useful to have: Appropriate safety equipment such as guard rails, harness gear, safety belts, hard hats, stable roof access ladder etc. Battery Drill (with Hammer Function) with Metal Drill Bits, Sockets and Drivers Metal and Masonry Drill Bits Flat Head and Phillips Head Screwdriver Silicone Lubricant Ropes Channel Lock Pliers Chalk/String Line Chalk or Marking Pen Screws Hammer Green Screw Plugs Pliers Pointy Nosed Pliers Teflon Sealing Tape Tin Snips Spanners 14 A/F and 16 A/F Screwdrivers Spirit Level Pipe Cutter or Hacksaw Tape Measure Caulking Gun PVC Cement PVC Primer This installation guide was designed to explain how to properly install a Rhino Solar system under normal circumstances. However, it cannot possibly address all situations or requirements. If you have any questions or issues, please contact your local Rhino Solar representative or in the absence, Boss Solar head office for assistance. 4

6 THINGS TO REMEMBER Determine the roof(s) where the panels will be installed, taking into consideration the space, orientation, roof protrusions and shading. The selected roof(s) should be exposed to the sun for the majority of the day, with minimal shading or obstructions. The best orientation depending on your hemisphere is outlined in the following table: Orientation Priority Northern Hemisphere Southern Hemisphere Best Option South Facing North Facing Second Best Flat Roof Flat Roof Third Best West West Forth Best East East Not Recommended North Facing South Facing Roof shading from trees, other buildings or obstacles must be considered when selecting a suitable roof installation site. However, a degree of shading can be compensated by installing a greater percentage of Solar Collector. Determine how the Rhino Solar panels will fit on the roof(s) and select an appropriate collector configuration. The most common and preferred configuration is in a continuous row. Remember to plan for any roof obstructions when selecting a collector configuration. Select the appropriate sized Rhino Solar panel(s) to suit your desired configuration and mounting location. Use larger panels where possible to minimise panel connections, lower installation time and reduce costs. Before undertaking any work, it is important to prepare a detailed Schematic Drawing/Diagram outlining the position and dimensions of the panel(s), Manifold system and Return pipe work in relation to the roof surface and pool location. Calculating how much Collector is required To identify how much collector will be required, you must first calculate the surface area of the pool and then determine the percentage of collector required. The following section will give you the information needed to calculate the total square metres of collector required. Calculating the Surface Area of a Rectangular or Square Pool To calculate the surface area of a rectangular or square pool multiply the width of the pool by its length (width x length = surface area). For example, if the pool is 9 metres by 5 metres then the surface area of the pool is 45 square metres (m²). 5

7 Calculating the Surface Area of an Oddly Shaped Pool To calculate the surface area of an oddly shaped pool: Visit Google Map Developers at Calculating the Amount of Collector Required The total quantity of collector required must be large enough and correctly positioned on the roof to heat the pool efficiently. For the average customer and installation, it is generally accepted that in cooler climates (such as San Francisco, Melbourne or Central Italy) a collector area equal to the surface area of the pool, i.e. 100% is required. In warmer climates (such as Florida, Queensland or Northeast India) 80% of the surface area of the pool should suffice. This amount may vary depending on several factors, including: Customers Expectation, Pool Blanket, Climate and the Available Roof Space To calculate the square metres of collector required, simple multiply the pools surface area (m²) by the desired percentage (%) and divide by 100. For example to provide 80% solar collector coverage for a 45 square metre pool, 36m² of collector would be required. Solar Collector Layouts and Balanced Flow The most common and preferred configuration is in a continuous row. However there are recommended limits to the number of collectors that can be installed in this way to achieve even flow throughout the array. The maximums are: Maximum Number of Panels/Banks for each Rhino Panel Model # Recommended Panels/Bank Maximum Panels/Bank Rhino Panel Model # R3/ R8/ R12/ R16/ R20/

8 Balanced Flow Wherever possible the return line should have the shortest possible run back to the pool to reduce heat loss as much as possible (Figure 1). If the system exceeds the maximum amount of panels per continuous row (see table on page 6), or is across separate roofs, splitting the system is very beneficial (Figure 2). Never use same end return as it reduces efficiency and doesn t allow for proper flow. (Figure 3). Figure 1: Reverse End Return Figure 2: Double Row Figure 3: Same End Return Flow rates should be between 1.8 to 4.8 litres per minute per square metre of collector. For a standard solar system, the ideal flow rate you should aim for is 4 litres per minute per square metre of collector. Once the Flow Rate has been calculated, select an appropriate pump size (based on flow rate and the required head height). The pump must have enough Kw/HP power to adequately supply the solar system with enough water to provide the recommended flow rate necessary for the collectors being installed. The generally accepted rates for a typical installation are shown in the table below: House Type Separate Circuit Simultaneous Single Story ¾ hp with TufFilta ½ hp - TufFilta optional Double Story 1 hp with TufFilta ½ or ¾ hp -TufFilta optional 7

9 Rhino Solar Panel Sizes Rhino Solar is manufactured as a mix and match modular system with 5 header lengths and 3 collector lengths. The 5 Header lengths are: Header Module Header Length (L1) H m H m H m H m H m The 3 Collector lengths are: Collector Module Collector Length (L2) Overall Panel Length (L3) C m 2.42m C3 3.05m 3.18m C4 3.82m 3.95m When possible*, the longest header pipe (H20) should be used, as it will result in: Reduced overall collector cost Lower labour, material and installation costs Greater surface area utilisation Reduced number of connections Reduced need for roof penetrations A more attractive installation *Unique installation requirements may see the need for a combination of different panel sizes to be used 8

10 Panel Sizes Surface Area in m 2 and the Boss ID Code The following table shows the net surface area of each Rhino Solar panel and it s unique Boss ID code which is displayed underneath in brackets. Panel Sizes Surface Area m 2 and Boss ID Codes in Brackets Extend Any Panel Length By using the unique Rhino Solar Panel Connector, you can extend the length of each panel by joining each length of collector. Now, rigid panels can be easily adapted to long vertical roof spaces without the need for additional header pipes or plumbing, saving you both time and money. 9

11 Plumbing Considerations Selecting the correct sized PVC pipe for your solar array is essential to ensuring the solar system runs efficiently. Selecting a pipe that is too small will result in the water flow being restricted and will unnecessarily reduce the flow rate to the collectors. A good rule of thumb is 4 litres per minute per square metre of Solar Panel. To select the correct sized pipe, use the following table as a guide: Flow Rate - Recommended Pipe Diameter (AS 1477 Class 9) Litres Per Minute Pipe Diameter (mm) Less than to to Please allow for all pipe work to thermally expand and contract. Depending on how the system is installed, you may have to account for both longitudinal and/or latitudinal expansion and contraction, the longer the pipe the more allowance for expansion is required. This is particularly important when installing pipes at an angle to each other. For example when pipes are joined using a 90 degree elbow, the installer should allow for both longitudinal and latitudinal expansion and contraction for both sections of joined pipes. One option is to install larger pipe clamps; this will allow the pipe to bend easily. Automatic Drain Down All Solar Systems should be installed in a manner that will allow the water to drain automatically and completely, each and every time the pump is switched OFF. This is extremely important as water left in the system can cause a variety of issues that may affect the integrity of your system. This is especially important in areas subject to freezing conditions. If the system cannot be designed to automatically drain down (possibly due to a unique roof design) then manual drain down valves should be installed in the plumbing or at the end of the bottom (supply) header. If this procedure is employed, it is important to train the pool owner in the proper drain-down procedure for winterising the system. Systems installed on flat roofs may require additional help when draining down by opening the collector connections and manually lifting the panel to empty the residual fluid. 10

12 HOW TO INSTALL RHINO SOLAR Step 1: Choose an appropriate position for the top roof mounts. Measure out a datum point and mark with a chalk line. To allow for proper drainage for winterisation, please ensure the line has a slight slope of approximately 25mm per 3 metres down towards the supply line If you are installing on a metal roof, mark the line ideally over a batten If you are installing on a tiled roof, ensure that the line is 50mm above the bottom of the tile, to allow any built-up debris above the header pipe to be washed away by the natural flow of the water. If the pipe is installed too close to the edge of the tile, the natural water flow would not be able to wash any built up debris away, therefore potentially causing roof leaks as the water builds up behind the debris and flows under the roof tiles Please note: If a slope is not possible, perhaps due to a unique roof design, then automatic drain down will not occur. In this instance, please ensure you install manual drain valves as needed Step 2: Using the diagram and table below, create a horizontal line where the bottom Roof Mounts and Aluminium Sliding Tracks will be installed (DIM A) and the position of the Fixing Track(s) (DIM B, C, D) 11

13 Step 3: Step 4: Step 5: Step 6: Move to the top chalk line and mark the location of the Roof Mounts, see Appendix 1 Marking the location of the Roof Mounts Install the TOP and BOTTOM Roof Mounts ensuring you are following the steps outlined for your particular roof surface. If you are installing on a metal roof see Appendix 2 Installing the Roof Mounts on Metal Roofs. If you are installing on a tiled roof, see Appendix 3 Installing Roof Mounts on Tiled Roofs Please note: The installation process is different when installing the TOP Roof Mounts compared to the BOTTOM Roof Mounts. The Bottom of the system Roof Mounts must be able to move to allow for thermal expansion and contraction Move to the first chalk line you created where the fixing track is to be installed Apply a generous bead of silicone to the peak of each corrugation along the marked line Step 7: Lay the fixing track over the bead of silicone, ensuring the correct orientation and press down firmly Step 8: Step 9: If required, install an appropriate screw through the track and silicone to secure to the roof Continue steps 6 to 8 until all fixing tracks are installed Fixing Track orientation Step 10: Step 11: Step 12: Assemble the collectors by following the procedure outlined in Appendix 4 How to Assemble the Collector. If you have to install the panels around an obtrusion, follow the steps outlined in Appendix 5 Installing Rhino Solar around Obstacles Hang the top headers of the assembled collectors into the bottom portion of the installed Roof Mounts To stop the panel/s from sliding off the roof, place the TOP portion of the Roof Mount over the BOTTOM portion and push them down lightly, do not insert the screws as you may need to remove them for panel to panel connections Step 13: Connect the panels together along the top header using the procedure outlined in Appendix 6: How to Connect the Solar Panels Together (Installing the Clamp Ring Assembly) Step 14: Step 15: Starting at one end of the top header pipe, install two (2) screws into the Roof Mount to secure its top to its bottom. Continue until all Roof Mounts along the top header have been secured Moving to the bottom header pipe, connect the panels together using the procedure outlined in Appendix 6: How to Connect the Solar Panels Together (Installing the Clamp Ring Assembly) Step 16: Step 17: Starting at one end of the bottom header pipe, push the TOP portion of the Roof Mount over the header pipe and BOTTOM portion of the Roof Mount Install two (2) appropriate screws into the Roof Mount to secure its TOP to its BOTTOM. Continue until all Roof Mounts have been secured 12

14 Step 18: Starting at the top, fix the panels to the roof by clipping them into the Fixing Track. To fix the panels to the Fixing Track: 1. Place the Clip-Lock over the collectors and Fixing Track 2. Press down firmly until you hear a click 3. Installed Clip-Lock Step 19: Connect the Supply and Return lines to the collector array in accordance with the steps outlined in Appendix 7 Connecting the Panel System to the Supply and Return Lines Step 20: Install the end caps on the opposite corners to the supply and return lines, see Appendix 8 Installing the End Caps for details Step 21: Run the Supply and Return lines from the roof to ground level, following the steps outlined in Appendix 9 Connecting the Supply and Return Lines from the Roof to Ground Level. Please ensure that you install adequate pipe clamps/straps to support the plumbing Step 22: Run the Supply and Return lines down the side of the building to the equipment pad, ensuring you use the appropriate 45 or 90 elbows and saddle clamps Step 23: Connect the Supply and Return lines to the existing Pool Filtration System, see Appendix 10 Connecting the Panels to the Existing Pool Filtration System Step 24: Step 25: Step 26: Step 27: Step 28: Install the Drain Tube, see Appendix 11 How to Install the Drain Tube for more details Install the TufFilta, see Appendix 12 How to Install the TufFilta Inline Solar Filter for more details Allow 24 hours for all adhesives to set prior to pressurising the system. To pressurise the system, follow the steps outlined in Appendix 14 Pressure Testing the System Now that the system is fully installed and pressure checked, complete your final operating and check-out procedures found in Appendix 13 Operating and Check-out Procedures If you encounter any issues, consult Appendix 15 Troubleshooting 13

15 Appendix 1: Marking the location of the Roof Mounts When determining where to position the top Roof Mounts, please remember to: *Optional Manual Drain Valve or End Cap Install the first Roof Mount 100 to 150mm in from the corner of the first collector Position subsequent Roof Mounts evenly with a gap no larger than 600mm. Additional Roof Mounts may be required for particularly steep installations or high wind regions If you are installing on a Metal Roof position the Roof Mounts on the peak of the corrugation and over a truss or batten capable of withstanding the expected external forces/pressures. They can be spaced anywhere along the top header to correlate with the spacing of the roof batten/trusses If installing on a Tiled Roof position on the valley of the tile Space them at least 51mm away from any Clamp Ring Assemblies (excepting the centre of the panel), to ensure horizontal expansion and contraction can take place Secure the centre of the system with two Roof Mounts either side of the central Clamp Ring Assembly* Figure 1 Figure 2 14

16 Appendix 2: Installing the Roof Mounts on Metal Roofs Installing TOP Roof Mounts on Metal Roofs This section provides steps for installing the TOP Roof Mounts on metal roofs. Before beginning please ensure you have the following components for each Roof Mount that is to be installed: TREMsil 870 Silicone Adhesive (or similar) One (1) Rubber Roof Pad One (1) BOTTOM portion of Roof Mount TWO (2) Appropriate Screws Step 1: Clean and dry the roof surface where the Roof Mount is to be installed. Step 2: Apply a generous bead of silicone to both sides of the Rubber Roof Pad and firmly place in its desired location. Step 3: Place the BOTTOM portion of the Roof Mount onto the Rubber Roof pad, with the open rounded section facing down the roof. Step 4: Secure the Rubber Roof Pad and the BOTTOM portion of the Roof Mount to the roof, by installing two appropriate screws at the top and bottom of the mount. Step 5: Repeat steps 2 to 5 until all top Roof Mounts are installed. 15

17 Installing BOTTOM Roof Mounts on Metal Roofs TREMsil 870 Silicone Adhesive (or similar) Two (2) Rubber Roof Pads One (1) Aluminium Slide Track One (1) BOTTOM portion of Roof Mount TWO (2) Appropriate Screws Step 1: Move to the horizontal line that was made for the BOTTOM Roof Mounts. Step 2: Mark the location of the bottom Roof Mounts and the Slide Track Aluminium Extrusions, ensuring you align them with the top Roof Mounts. Step 3: Starting at one end of the bottom header, mark where the top and bottom of each of the Aluminium Slide Tracks will be positioned. Please Note: The BOTTOM Roof Mount should sit centreline in the Aluminium Track, in a manner that will allow for vertical expansion and contraction of the panels. Step 4: On an appropriate surface, carefully drill a pilot hole into the top and bottom of each Aluminium Slide Track and set aside. Step 5: Starting at one end, clean and dry the roof surface where each of the Roof Mounts is to be installed. Step 6: Apply a generous bead of silicone onto both sides of two (2) Rubber Roof Pads and firmly press one (1) Rubber Roof Pad to the top of the marked line and one (1) to the bottom of the marked line. Step 7: Place the Slide Track Aluminium Extrusion over the Rubber Roof Pad and, using an appropriate screw, secure to the roof. Step 8: Slide the bottom section of the Roof Mount into the Slide Track Aluminium Extrusion, with the open rounded section facing up the roof. Step 9: Stop the Roof Mount from sliding out by drilling a second screw into the bottom of the Rubber Roof Pad and Slide Track Aluminium Extrusion. Step 10: Repeat steps 5 to 9 along the bottom header pipe until all Roof Mounts are installed. 16

18 Appendix 3: Installing the Top Roof Mounts on Tiled Roofs Installing Roof Mounts on Tiled Roofs This section provides steps for installing the TOP Roof Mounts on tiled roofs. Before beginning please ensure you have the following components for each Roof Mount that is to be installed: One (1) LONG Tiled Roof Bracket One (1) Short Tiled Roof Bracket Four (4) Button Wafer Head Screws One (1) BOTTOM portion of Roof Mount Step 1: Lift the tile above the line marked for the TOP Roof Mounts and slide the LONG Roof Bracket between the two tiles in the valley of the bottom tile. Ensure the Roof Bracket hooks onto the roof batten and apply a generous bead of silicone underneath and on top of the Roof Bracket to insulate it against the tile. Step 2: Lower the tile back down to lock the roof bracket into place. Step 3: Slide the bottom portion of the Roof Mount onto the installed Roof Bracket, with the open rounded section facing the appropriate orientation. Figure 1 Step 4: If installing the top of the system roof mounts, secure the bottom portion of the Roof Mount in the desired location using appropriate screws. If installing the bottom of the system roof mounts, DO NOT fasten them to the tile brackets so as to allow for thermal expansion and contraction. Step 5: Lift the tile below and slide the SHORT Roof Bracket underneath until it hooks onto the roof batten below (Figure 2). Lower the tile back down to lock the roof bracket into place Figure 2 Step 6: Secure the SHORT Roof Bracket to the LONG Roof Bracket using two (2) appropriate screws (Figure 3) Step 7: Repeat steps 1 to 6 until all top Roof Mounts are installed. Figure 3 17

19 Appendix 4: How to Assemble the Collector Cobra Collector Run(s) Header Pipe(s) Barb Locks Can of Silicone spray The following section offers step by step instructions for assembling the Rhino Solar collectors: Step 1: Lay the top header pipe down on a clear flat surface and apply Silicone spray to holes along the entire length. Be careful to control overspray so as not to slip over. Step 2: Starting at one end of the top header pipe, push the collector into the appropriate connection ports ensuring you inspect the collector to ensure all Red Silicone Barb Seals are present and intact. If not, please replace it/them using one of the replacement seals provided. Step 3: Insert the Barb Lock into the correlating slots ensuring the raised lip is facing towards the collector and push down firmly until you hear a click. Step 4: Continue this process along the header pipe until all collectors have been installed and secured. Step 5: Lay the bottom header pipe down, spray with Silicone and insert the uninstalled end of the collector into the appropriate connection ports, first ensuring that all Red Silicone Barb Seals are present and intact, if not, please replace them. Step 6: Insert the Barb Locks until all collector runs have been secured. 18

20 Appendix 5: Installing Rhino Solar Around Obstacles There are two options when you need to install around an obstacle, you can either employ the traditional PVC pressure pipe method or you can install Rhino Manifold Plugs. The decision to use either method is up to the installer, however Rhino Manifold Plugs can be a more convenient, faster and aesthetically appealing option for smaller obstructions. Rhino Manifold Plugs To install Rhino Manifold Plugs: Step 1: Locate and mark the collector tubes that are in the path of the obstruction. Step 2: Carefully strip or cut away the marked tubing and discard. Please ensure that you do not damage the remaining tubing on the panel. Step 3: Insert the trimmed down collector and Manifold Plugs into the header pipe, first ensuring that Red Silicone Barb Seals on the collector and Manifold Plugs are present and intact. If not, please replace it/them using one of the replacement seals provided. Step 4: Secure the collector and Manifold Plug/s by inserting a Bark Lock into the correlating slots and pushing down firmly until you hear a click. PVC Pipes To use the traditional PVC pressure pipe method to circumnavigate obstacles: Step 1: Measure the length of the obstruction and cut two pieces of 40mm PVC pressure pipe long enough to circumvent the obstacle. You may need to take an additional 4cm into consideration, to account for the PVC Pipe Couplings. Step 2: Once you have deburred the PVC pipe(s), cement two (2) PVC Pipe Couplings to either end. Ensure that you use a good quality, multi-purpose cement. Step 3: Connect the PVC pipes and coupling to the appropriate panels, using four (4) Clamp Ring Assemblies, see Appendix 6 for instruction on installing the Ring Clamp Assembly. Step 4: To prevent sagging, install a 50mm (2 inch) pipe clamp on both the top and bottom pipes, this may not be necessary if the distance is less than 100mm (4 inches). 19

21 Appendix 6: How to Connect the Solar Panels Together (Installing the Clamp Ring Assembly) 1 x Top Portion of the Ring Clamp Assembly 1 x Bottom Portion of the Ring Clamp Assembly (with Hexagon Recesses) 1 x Silicone Seal Ring 2 x Button Head Screws 2 x Hexagon Nuts 1 x HEX 3 x 50mm Drive Bit with Cordless Impact Driver To install the Clamp Ring Assembly: Step 1: Clean the groove of the Header/s, End Cap or PVC Coupling with a clean rag. Step 2: Insert the Silicone Seal Ring into the groove of the End Cap, PVC Coupling or Header Pipe (if you are joining panels together). Step 3: Push the component with the inserted Silicone Seal into the groove of the Header Pipe you wish to attach it to. Step 4: Push the hexagon nuts into the hexagon recesses, located on the Bottom Portion of the Ring Clamp Assembly. Step 5: Place the bottom portion of the Clamp Ring Assembly (with the installed nuts) under the components you are connecting. Step 6: Place the top half of the Clamp Ring Assembly over the collectors and squeeze the top and bottom portions together, ensuring the drill holes are aligned. Step 7: Using the HEX 3 x 50mm Drive Bit with a Cordless Impact Driver, bolt the top and bottom portions of the Clamp Ring Assembly together using the two (2) supplied button screws (Figure 5). Tighten until secure. 20

22 Appendix 7: Connecting the Panel System to the Supply and Return Lines Step 1: Locate the corners of the solar system where the Supply and Return lines are to be connected. The Supply Line is connected to the bottom header, on the side farthest from the pool pump. The Return Line is connected to the top header pipe, on the side closest to the pool pump. This gives the heated water the shortest path back to the pool. Step 2: Attach a PVC Coupling to the corners where you wish to connect the Supply/Return Line using the Clamp Ring Assembly (see Appendix 6 for instructions). Please ensure that the Supply and Return pipe work is connected using good plumbing techniques and high quality equipment and supplies. Please also ensure that all pipe work has been adequately supported using pipe clamps. Appendix 8: Installing the End Caps Caps are installed at the end of the solar array opposite the corners where the Supply and return lines are located. To install the End Caps: Step 1: Locate the corner of the panel where the end cap is to be installed. (This is the corner opposite the supply and return lines) Step 2: Clean the groove of the header and End Cap Rhino End Cap Step 3: Insert the Silicone Seal Ring into the groove of the header Step 4: Insert the groove of the End Cap into the Silicone Seal Ring and push until fully inserted Step 5: Place the bottom portion of the Clamp Ring Assembly under the collector and End Cap, with their lips resting in the internal groove of the Clamp Ring Assembly Step 6: Place the top half of the Clamp Ring Assembly over the collector and End Cap Step 7: Squeeze and hold the top and bottom portions together, ensuring the drill holes are aligned Step 8: Bolt the top and bottom portions of the Clamp Ring Assembly together using the supplied screws 21

23 Appendix 9: Connecting the Supply and Return Lines from the Roof to Ground Level While these steps are useful, they cannot possibly cover every type of installation. Therefore the installer may need to get creative and adapt these steps to suit unique roof designs or unusual equipment pad locations. Before beginning, it is important to note that: Return pipes should be the shortest run All plumbing should be as direct as possible Aesthetically the supply and return pipes should be kept as close to the gutters, valleys and ridges as possible Plumbing skills and knowledge will be required, particularly when installing over hips or valleys The use of plumbing fittings should be kept to a minimum Where possible 45 elbows should be used instead of 90 elbows, as they are less restrictive to the water flow All pipes should have a slight downhill slope to aid in automatic drain down If needed, pipework must be secured with additional Plumbing Clamps as the systems manual hardware is not designed to support the additional weight of the plumbing The four corners of the system must be secured To connect the supply and return lines to ground level: Step 1: If not already installed, cement a PVC 90 elbow to the return line using a high quality, all-purpose primer and cement. This elbow should face down towards the bottom header. Step 2: Moving to the Supply line, cement a PVC 90 elbow facing away from the system Step 3: Identify where the Supply and Return pipes will go over the edge of the roof and mark this spot with chalk. If possible, these pipes should be installed at the exact points where they will fasten into the existing system or into pipes coming from another location. Please note: This may not always be possible. In this circumstance, the installer may need to use their skills and knowledge to modify this step. Step 4: Accurately measure and record the distance from the Supply and Return elbows to the marked points. Ensure that you include the depth of the elbow socket in your measurements. Step 5: Cut your PVC pipes to suit the measured lengths. Clean and deburr the pipes and insert the elbows. Step 6: If you are not experienced in plumbing PVC pipe, it is a good idea to lay out and connect the pipes and fittings before cementing them. This allows you to identify and fix any potential errors. Step 7: Examine the system and ensure the pipes are as short, straight, and tight to the building as possible. Once you are satisfied, go back and cement all fitting and pipework. Ensure you double check that all parts have been properly cemented. Step 8: Adequately secure all pipe work with the appropriate pipe clamps, bolts and screws. 22

24 Appendix 10: Connecting the Panels to the Existing Pool Filtration System Not every system will be like the one outlined in the diagrams below. Some will have additional equipment, a different type of filter or the pipes may be reversed. Either way, the diagram should help you to gain an understanding of the flow of water from the pool, through the system and back to the pool. These diagrams outline all of the components necessary to appropriately plumb the system. Please study and familiarise yourself with the diagram and required components. Please note: Always plumb the Non-Return Valve after the filter to prevent the filter being backwashed by the water draining down from the collector when the pump is switched OFF Always use a good quality all-purpose primer and cement Ensure that you properly secure all pipework Try to keep the system as straight, tight and clean as possible Separate Circuit Configuration 23

25 Simultaneous Configuration Manual System *Optional if Required 24

26 Typical Plumbing Schematic Filtration, Solar and Pool/Spa Heating 25

27 Typical Plumbing Schematic Filtration and Solar with Variable 3 Speed Pump 26

28 Appendix 11: How to Install the Drain Tube a Drain Tube will allow the collector and supply pipes to automatically fully drain back to the pool when the pump is switched off. Before beginning please ensure you have: Two (2) Grommets Two (2) Header Barbs Two (2) Collars One (1) 150mm (approx.) length of tube To install the drain tube: Step 1: Mark the location of Drain Tube. The Drain Tube should be installed between the supply and return pipes approximately one metre above pump level Step 2: Drill an 8.5 mm hole in the PVC supply and return pipes in the appropriate position and orientation Step 3: Ensure the drilled wad, swarf and burrs are removed to prevent them from entering the system Step 4: Insert the rubber grommets into the holes tapered end first Step 5: Insert the short end of the header barbs into the grommets Step 6: Slide the two Collars over the collector tube with the lips towards the cut ends Installed Drain Tube Step 7: Push the collector tube onto the barbs Step 8: Slide the collars over the tube and barbs Please note: Dipping the components in soapy water can make this process easier 27

29 Appendix 12: How to Install the TufFilta For systems that employ a separate solar pump, independent of the pool filter circuit, it is recommended that a TufFilta is installed on the discharge side of the solar pump. The TufFilta should be positioned to allow for easy access during maintenance and away from any equipment that may be affected by pool water overflowing or splashing during the replacement of the internal cartridge element. If a TufFilta is installed, an isolating valve should be positioned on the discharge side, this enables the cartridge element to be removed and replaced without drenching the equipment or the person performing the task. TufFilta During the swimming season, the TufFilta should be checked for debris at least once a month or as often as required for the particular installation. If you notice debris collecting in the TufFilta it is recommended that the cartridge be replaced and the bowl cleaned. (replacement filters are available through Boss) TufFilta Installation Recommendations When installing the TufFilta, ensure that is oriented correctly (as per the image above) and that the flow direction arrow (located on top of the TufFilta ) is facing the correct direction. Please Note: most installers incorrectly assume that the solar pumps standard lint pot is sufficient to protect the solar system from blocking with foreign matter. However, experience in the field has extensively proven that this is not the case. It should be noted that Australian Standards AS Section 6.2 clearly state that "A filter or strainer shall be provided to remove solids or debris from the water entering the solar circuit. 28

30 Appendix 13: Operating and Check out Procedures The system should now be installed and pressure checked. Before switching the system on, it s a good idea to do one final visual inspection. Walking down the entire system, check that: The fittings and fixtures are primed and cemented properly All valves are installed correctly and in the right positions The system properly secured to the roof in a manner that will still allow for thermal expansion and contraction Screws and bolts are secure and penetrations sealed Roof Mounts installed and bolted correctly All pipework has been properly secured and supported All collectors have been secured top and bottom with Barb Locks All collectors have been snapped into the Fixing Track with Fixing Clips The Fixing Track has been secured to the roof (if required) No part of the panel is rubbing against the roof surface. If it is, it can cause damage to the roof and/or panels The system will automatically drain or that it is installed with manual drain valves The Automatic Controller (if installed) has been tested System appears neat, tidy and of high quality Appendix 14: Pressure Testing the System Commissioning the system is one of the most important steps for any solar installation. Performed correctly, commissioning should highlight any faults within the system prior to hand over. To pressure test the system: Step 1: Allow 24 hours for all PVC Cements/adhesives to set prior to commissioning the system. This time can be used to clean the job site. Step 2: Prime the pump by filling the lint pot with water, once filled start the pump via the manual mode on the Digital controller. Step 3: Once primed, air should purge from the system and back to the pool via the pool return outlet for only a short period of time. Step 4: After a minute or two inspect the pools return outlet. If bubbles continue to flow endlessly, it may be an indication that air is entering the system via the VacRel see Appendix 15: Troubleshooting for the solution. Step 5: Once the bubbles reliably stop, check the TufGauge Pressure Gauge is reading between 50 and 100 kpa (7 and 14.5 PSI). Step 6: Check the system and panels for leaks. The suggested method is to inspect the roofs surface for water dribbling towards the gutters. By following the dribbles up the roof you will generally find the source of the leak. Repair and re-test as necessary. Step 7: Once you are satisfied that the system is running properly, switch it off and listen to the VacRel. Air should be entering the system through the VacRel and water should be draining back to the pool. 29

31 Appendix 15: Troubleshooting Air Bubbles are appearing in the pool returns when the system is running Cause: Air bubbles are a result of air entering the system. This could be caused by air entering through the pump or through the vacuum relief valve, you can find out what the cause is by: Listening to the pump if the pump is making a lot of noise, then it is likely that air is being sucked into the system through an air leak on the supply side of the pump. This makes the pump work harder trying to move the water through the system and therefore it will make more noise as a result. Listening to the VacRel (Vacuum Relief Valve) inspect the VacRel by listening for the sound of air being sucked back into the system. This is caused by insufficient water pressure in the system which is stopping the valve in the VacRel from closing and therefore allowing air to be drawn into the water as it flows by the valve. Solution: When air is entering through. The pump Check that the pumps filter basket lid is on tight. If the lid is on tight, but you still suspect air is entering through this point, remove, clean, lubricate or replace the O- ring on filter basket as needed If the pump has a clear lid, look inside and see if air bubbles appear. If they are present, use a garden hose to run water over the pumps lid and joints and look to see if the bubbles stop. If they stop, locate and fix the leak. If the pump does not he a clear lid. Listen to the pump noise for a smoother operating sound, locate and repair any leaks If the pool is using a suction type pool cleaner, try removing it to see if the air bubbles clear up. If they do, only use the cleaner while the system is turned OFF The vacuum relief valve Being careful not to lose any of the components, remove and clean the VacRel as needed Clean the filter and backwash to reduce pressure Adjust the (HBV) on the return line to increase the back pressure on the system 30

32 When running my hand over the panels, some areas are hot to touch Cause: While conducting your Operating and Check out Procedure, you were instructed to run your hand over the system to see if any part was particularly hot to touch. While it is normal for the top of the panels to be warmer than the bottom, no part of the panel(s) should be hot. Hot spots indicate that there is no/low water flow through this part of the collector. This can be due to two factors, issues with the pump or improper installation, you can find out what the cause is by: Checking your calculations go back and check that you have calculated and selected the right sized pump for your particular installation. If you have not, then this is likely to be the problem. If your calculations are correct then your issue is most likely going to be due to improper installation Solution: When the issue has been identified as: The pump Be sure that the filter is clean and backwash to reduce pressure The pump may not be big enough to provide the system with enough water. You can check this by using a flow meter. Increase the pump horsepower as required If the pool is using a suction type pool cleaner, try removing it to see if this eliminates the issue. If it does, only use the cleaner while the system is turned OFF Improper installation If the system is a single row array with adequate flow, try adjusting the (HBV) back on the return line to provide more back pressure and even out the flow throughout the panels Check that you have not exceeded the maximum allowance of collectors for a continuous row. If you have, than change the array to an appropriate double row or single row split feed configuration If the installed system is a double row or single row split feed system with an adequate flow, try installing a ball valve on the return side of the set of panels that are the coolest to the throttle. Adjust the ball valve to back the flow through the system and force more water through the warmer panels. 31

33 The water coming from the return outlets of the pool is not as warm as it should be Cause: Use the back of your hand to feel the temperature of the returning water, if you notice it is not coming back warmer, it may be an indication that water is flowing too quickly through the system. If water flow is too great the water will not get enough time to properly heat up before it is returned to the pool. Solution: Adjust the three-way valve on the return side of the system to push the water back up into the system. This will allow more time for the water to circulate and heat up. It is also important to note that the pool water will not increase in temperature as much during the cooler months of the year, or on cool, windy or particularly cloudy days. This is due to normal seasonal operation changes and cannot be helped. There is a slight leak from the silicone seal during pressure testing Cause: During installation small pieces of debris have fallen onto the sealing taper or seal and is resulting in a slight leak. Solution: Mark which collector is leaking and switch off the pump. Using a flat tipped screwdriver, carefully remove the barb lock and pull the collector out of the manifold. Inspect to ensure all silicone seals are in place, intact and clean. Once complete, insert the collector back into the manifold and secure using the barb lock. 32

34 Appendix 16: Maintenance Schedule Service Maintenance Schedule Maintenance Issue - Service Procedure Monthly Quarterly Annually TufFilter / Strainer: Depending upon your pool usage and level of debris, the TufFilta / Strainer will need to be checked and cleaned regularly Leaks: Check for leaks on a regular basis as leaks can corrode metal roofs and gutters. Leaks should be repaired as soon as possible. Non-Return Valve: The non-return valve (see plumbing diagrams) is a critical system component. Check that the 6mm hole drilled in the flap has not become blocked and that the collectors drain fully when the pump stops. Vacuum Release Valve: The vacuum release valve (9) is a critical system component. It should be checked that it is functioning correctly and that collectors drain fully when the pump stops. The collectors and/or piping should never appear collapsed (concave) by negative pressure. Plumbing Degradation: Plumbing should be checked for signs of UV and/or chemical damage. Replace as needed. Debris Accumulation: Check that there is no build-up of debris around pipe work or collectors, and that water has a clear path to run down. Winterising System: You may need to prepare your system for winter dormancy each year, i.e. open the Manual Drain Down valve and empty the system of all residual water. 33