Fully Aboveground Installations

Transcription

1 INSTALLATION INSTRUCTIONS Fully Aboveground Installations Partially In-Ground Installations Fully In-Ground Installations Poolside Water Quality System

2 Installation Instruction Booklet Information Endless Pools, Inc. provides for every aspect of an Endless Pool project. This manual assists in the installation process. This manual should be used in conjunction with the Supplemental Guides. Additional available resources including The Introduction Booklet, The Planning Guide, and Technical Specifications are available to you. A series of Supplemental Guides follow this manual. Copies of these are included in the Owner s Manual and online at These guides are referenced in the following installation instructions. In addition we encourage installers to call our Customer Service Department at (800) before beginning installation to register their project and sign up for weekend technical support. Please be advised that gloves and safety goggles should be worn during the installation of an Endless Pool. Please take into consideration the following before proceeding: Endless Pools will provide you an electrical whip to connect between the heater controller pool-side and the hydraulic power unit. This length is typically the same length as your hydraulic hose. If you did not order your hydraulic hoses to be included with your pool shipment, please be aware that your pool installer and electrician need to agree upon the location of your power unit, and that we'll provide this package to you once that decision is made. If you have chosen our optional lights or jets: the ideal placement of each of these lights and jets can vary for each person, and you will need to cut the holes in panels to meet your needs. We have provided all of the proper drill bits for you to easily accomplish this. You should also consider that you will need to access these through your finish work in the future. Please see the Supplementary Guides for those options included in this Owner's Manual for additional information. Installation Instructions Table of Contents Pool Arrival and Inspection Site Preperation Optional Deeper Wood Platform Optional Stainless Steel Floor Structure Exploded View of Panel Assembly Optional Stainless Steel Formwork Assembly of Pool Panels (Overview) Panel Assembly Instructions Anchoring Optional Insulation Installation of Reinforcing Channels Installation of the Liner Hanger Optional Liner Hangers Foam Underlayment Liner Installation of Cast Composite Internal Components Installation of Stainless Steel Internal Components Installation of Poolside Water Quality system Keypad Installation Wiring Power Unit Hydraulic Fluid Bonding and Grounding Hydraulic Run Connections Optional Retractable Security Cover System Optional Hydrotherapy Jets System Optional Underwater Lights System Optional Corner Step Optional Full Depth Stair Optional Swim Mirror

3 1. Pool Arrival and Inspection The Standard Endless Pool arrives in three packages: a skid of 6 pool panels weighing approximately 850 lbs., a 4' x 8' x 4' high crate weighing about 1,150 lbs and a pair of 6 5/8" wide steel reinforcing channels. Most shipping companies will lower the containers to the ground with a hydraulic lift gate on their truck; the pool can remain in the containers until you are ready to begin installation. Please contact our shipping department prior to shipment to answer any questions you may have. Since every delivery is slightly different, and depends to a large extent on site conditions, it is important to speak with our shipping department well in advance to reduce the chance of surprises. Pool crate, panels and channels shown as they will arrive. Upon arrival, the packages should be inspected for external damage. Should there be visible damage, you must complete a damage-claim report provided by the truck driver. Please call the Endless Pools shipping department immediately at (800) The pool components are not damaged by freezing conditions and may be stored outside under a tarp for an extended period prior to installation. 2. Site Preperation It is important that your Endless Pool be installed over a smooth, level concrete slab that is capable of supporting 200 pounds per square foot for a flat bottom pool. The thickness and the quality of the concrete slab will effect the anchoring method. The floor must contain no voids or bumps and shall be relatively smooth and level. For those installing the Custom Deep End Option, the walls of the deeper section must also contain no voids or bumps. The corners at the depth change should be eased slightly (approx 1/4"). If a new slab is poured, consult your local electrical codes regarding grounding and bonding. Many areas require a bonding wire to be attached to the reinforcing bar that is buried in the concrete. Drainage needs to be provided around the pool and near the water quality equipment. It is important to be prepared for the unlikely event of a leak. It is ideal to install floor drains in the area just outside the pool panels, but not directly under the panel or the pool itself. In installations where this is not possible, it is recommended to install a secondary containment system to help divert water to a more desirable location. It is extremely important to ensure that any water that may reach the bottom flange of the pool panel, by splashing, run off, or accidental leakage, be drained away immediately. With the bottom flange of the pool panel standing in water, corrosion may occur over time. It is worth the time and effort now to install a drainage system rather than be unprepared in the event of a mishap. 3. Optional Deeper Wood Platform Sometimes customers desire a custom deeper pool completely aboveground without excavation. This can be done by constructing a wooden platform using a drawing supplied by Endless Pools, Inc. This system is described in the Optional Deeper Wood Platform Supplemental Guide. An optional Deeper Wood Platform Hardware Kit is available through Endless Pools. This solution only applies to platforms that are 12" or less in height. Any platform of greater height should be designed by a local engineer. Endless Pools, Inc. can not take responsibility for the structural integrity of platforms constructed by others. Also note that deeper pools hold more water and exert a greater load on the floor upon which they rest. Endless Pools, either deeper or flat bottomed, should not be built on upper stories without a structural engineer involved who is willing to stamp the drawings. Outdoor storage with tarp. To begin installation, or to move pool components, begin unpacking the pool. Using a hacksaw or tin snips, remove the steel packing straps encircling the pool panel skid. The wooden top and sides of the crate may be removed with a phillips-head screwdriver. 4. Optional Stainless Steel Floor Structure The Endless Pools, Inc. optional stainless steel floor structure provides a simple cost effective alternative to a poured concrete floor system. This system is an appropriate alternative if access to your pool site is a problem for concrete trucks or the distance is too great to haul concrete. Built to fit your specific pool size, the stainless steel floor system can be used for flat bottom or custom deeper pools. This system has been engineered to withstand the weight of the pool for pool configurations that are partially in-ground or fully above ground. The stainless steel has a foam backing providing added insulation for your pool. Minimal excavation is needed for above ground or partially in-ground pools, making this the ideal solution for a speedy installation. It is delivered with your pool as a kit of parts, which are assembled on site. Refer to the Supplemental Guide for step by step installation instructions. 3

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5 5. Optional Stainless Steel Formwork The Endless Pools Stainless Steel Formwork eliminates the need to build and then strip out wood forms when pouring concrete and allows both floor levels to be poured at the same time; eliminating the cost associated with a second concrete pour. The Stainless Steel Formwork is factory-built to specific dimensions allowing for a more precise custom deeper area. While most commonly used outdoors, the Stainless Steel Formwork can be used indoors. The formwork is delivered with your pool as a kit of parts, which are assembled on site. The panels are 2 and 3 in length assembled in combinations to create the deeper area. The panels are 12 or 18 high depending on the desired depth deeper area. Please refer to the Stainless Steel Formwork Supplemental Guide for more detailed installation instructions. 6.Assembly of Pool Panels (Overview) Bolt the panels together leaving access at the front of the pool for service. If jets, lights and/or a retractable security cover are to be installed, outside access to additional walls will be required. Access requirements are described in The Endless Pool Planning Guide. Packed in the skid of panels is the Pool Panel Hardware Kit that contains all of the pieces necessary to assemble the pool panels and anchor them to the concrete floor. Pool Panel and Hardware Kit. of the pool panel for access both during and after installation. Only 8" of horizontal clearance is required for the bottom 18" of the front panel and 7" of clearance is required for the other 3 sides of the pool disregarding for the moment the requirements for access for jets, lights, or the retractable security cover. Long side end flanges bolted together with a gusset. Hardware in Panel Kit. If anchoring down to the concrete is impractical and you have a flatbottom pool, you may have selected optional Tension Straps. If they were ordered with the pool they would be packaged in the pool crate. When an Custom Deeper Endless Pool has been selected, the panel enclosure will be anchored down to the concrete and there will be a concrete pad with a formed deeper section inside the panel enclosure. If you have 54" panels please refer to the Deeper Panel Supplemental Guide 7. Panel Assembly Instructions On a level concrete slab assemble the 6 wall panels. The smooth wall of each panel should face inward. The front panel-the panel towards which you will be swimming-has cutouts for the skimmer, jet suction, water-return fitting, and 2 hydraulic hoses. Leave at least 18" of horizontal clearance from the front panel surface for the top 24" The 6 wall panels will form a pool enclosure with inside width of 7' 0", 8' 0", 9' 0" or 10' 0" and inside length of 12' 0", 13' 0", 14' 0", 15' 0", or 16' 0" depending on the pool size selected. Each panel has a 3-1/2" bottom flange and a 6-1/2" top flange. Consequently, the outside bottom dimensions of the pool are 7" greater than the inside dimensions and the outside top dimensions are 13" greater than the inside dimensions. Gusset End Flange Top Corner Angle Outside Corner Angle Fig 4.3: Outside corner angle, top corner angle, gusset and panel end flange shown. 5

6 straight. Then measure both diagonals. Shift the panels by pushing at the corners until the difference is less than 1/8". If the pool is to be positioned next to a wall some bolts will be hard to reach. In this case, one side may be bolted together first and then slid back against the wall. You will probably want to use blocking angle rather than anchor bolts for this inaccessible condition. Take care when sliding the enclosure against a wall to leave enough room for the coping and for the 18" of access at the front. Loosely bolt together the corner angle, top corner angle, gusset and panel. On the long sides, the end flanges of the 2 adjoining panels bolt together directly. The 4 corners of the pool are held together by 4 outside corner angles each 39" long. Install the 10 gussets at every panel intersection 1 on each side and 2 in each of the 4 corners. Do not install these gussets between the panels. Install the 4 top corner 8.Anchoring Care should be taken to ensure that the pool is square before securing the panels to the concrete. The bottom flange of each panel has pre-drilled holes to accept the 3/8" x 3" anchor bolts provided. An absolute minimum of 10 anchor bolts are required. When possible more anchor bolts should be used with an emphasis on the centers of the panels and the center of the long sides of the pool enclosure. If the pool is to be positioned next to a wall some bolts will be hard to reach. In this case, one side may be bolted together first and then slid back against the wall. You will probably want to use blocking Completing pool enclosure. Note cut-outs on front panel. angles in each of the 4 corners. Loosely bolt together the entire enclosure, then check that the top flange of each panel is flush with its neighboring panel before tightening the bolts. Check that the panels come together evenly at the corners. There is some play in the bolt holes to allow for adjustment. Once the panels are bolted together to form the pool enclosure make sure that the enclosure is square. First check that the long walls made from 2 panels are Drilling through foundation to secure blocking angle. angle rather than anchor bolts for this inaccessible condition. Take care when sliding the enclosure against a wall to leave enough room for the coping and for the 18" of access at the front. When the Custom Deeper Pool Option has not been selected and it is desired not to drill into the concrete floor, Tension Straps may be Bolting the pool enclosure together. Note cut-outs on front panel. Blocking angle installed with pool panel pushed flush against it. 6

7 used. These are ordered from Endless Pools, Inc. for any size pool. The kit for a standard 7' x 14' pool consists of 4 stainless steel tension straps, 1 long (14' 7") and 3 short (7' 7"). These straps run under the bottom flanges and along the floor, connecting to the outside lips of the flanges on each side. They are designed to resist the hydrostatic force of the water in the pool. Assemble the panels as described above placing the Tension Straps under the bottom flange. The vertical lip of the bottom flange of each panel has pre-punched holes to accept the 3/8" nuts and bolts which are used to secure the tension straps. This is the same hardware used to bolt the panel enclosure together. The Tension Straps should connect between the centers of opposite panels and at the joint in the long walls. Tighten the nuts and bolts securing the tension straps before sliding the pool Rigid foam insulation being installed between the support struts. 10. Reinforcing Channel The 2 channels, each 6 5/8" wide, fit over the top flanges of the two long sides of the pool. The channels bridge the joint between the panels on the long walls. Check that the enclosure is square. Put the channels on loosely. Check to see if either channel has a sharp edge or burr and be sure to locate this on the outside face of the pool or file it down and/or cover the sharp edge securely with duct tape. The channels will be secured down later with the self-drilling fasteners provided in the liner hanger kit. These channels are structural and must be installed correctly to withstand the hydrostatic load. Fig 5.2:Tension straps in place under pool. into a corner. If a strap bows up check the dimension of the pool enclosure at the bottom as the panels may be bowed in. If necessary, you may loosen a tension strap bolt on the accessible end of one tension strap and pull the strap taut. Be sure to keep the nut and bolt in place and tighten them as you fill with water and the panels push outward. Concrete can also be used to anchor the pool to the slab provided that the pool is at least partially recessed and the walls of the pit that the pool sits in are strong enough to resist this outward load. Do not pour concrete to bear against a non-structural wall. 9. Optional Insulation (by others) To conserve heat and reduce operating costs we strongly recommend that the Endless Pool be insulated with rigid foam. Simple 2" thick rigid foam insulation boards are usually adequate and are available from any building supply house. Check with your supplier for a recommended adhesive appropriate for the type of rigid insulation that they supply. Be sure to leave access to all of the panel cutouts when you are installing the insulation. If the pool is to be installed outside in a cold climate, you might consider using two layers. Be sure to consider the danger of freezing for any pipes running outside the insulation. If you have selected the hydrotherapy jet option and your pool is exposed to freezing conditions, please refer to Hydrotherapy Jet Supplamental Guide for additional insulating measures. Installing the structural channels. When possible, the walls of an Endless Pool should be braced laterally before filling with water to reduce outward deflection when the pool is filled with water. The steel reinforcing channels supplied by Endless Pools Inc. are sufficient to withstand the hydrostatic load but the pool walls will deflect slightly without bracing. When a rigid coping such as tile is planned this deflection is undesirable. For inground or partially in-ground Endless Pools simply brace or shim laterally back to the walls of the pit before filling. Be sure not to brace back to a load-bearing wall unable to resist this lateral load. Please call Endless Pools Customer Service with any questions. 7

8 11a. Liner Hanger The aluminum liner hanger installs around the perimeter of the pool panel enclosure. The liner hangs from this extrusion using a bead that is heat welded into the top edge of the liner. The liner hanger system is packaged in the pool. Self-drilling fasteners are included in the kit along with a nut driver attachment for your drill. Once the corner lengths are secured, install the remaining two lengths of liner hanger along the side of the pool. These pieces vary in length, depending upon your pool size, so they may need to be trimmed. It is important that the gap at any joint between two liner hanger pieces be no greater than 1/8. Caulking the liner hanger on the bottom. Installing the triangular inside corner supports. Because the height of the 2 steel reinforcing channels is slightly higher than the surrounding top flange, we provide PVC shims inside the kit to place under the liner hanger and to shim the hanger up to the level of the channels to keep the whole system level. The shims can be cut with a hacksaw or scored with a utility knife and snapped to fit the size of the pool. Over the channels, the fasteners should be drilled through the channel and the flange. You may use a pilot hole if you wish. Elsewhere, the fasteners must be drilled through the shims and the panel flange. Securing the liner hanger to the top of the pool panel Install the 4 triangular inside corner supports, using the self-drilling fasteners provided. Take the four 8 lengths of liner hanger that have been notched in the center, and bend these pieces so that they will fit and be secured in each corner over the triangular inside corner supports. Use two self drilling fasteners and PVC shims to secure the small corner length first, then secure the rest of the hanger to the end and side panels, using shims when not securing through the channel. The hanger pieces should be flush with the inside of the reinforcing channel and will protrude into the pool the thickness of the channel everywhere else. Caulk the gap between the liner hanger and the panel to ensure that no water falling on the top flange of the pool panel can work its way down behind the liner. (With the same objective in mind, later caulk the joint between the top of the liner hanger and the coping that you install over the entire top flange of the pool.) 11b. Optional Lights, Jets and Liner Hangers An Endless Pool is usually customized to meet the needs of the end user. Pools of different lengths and widths are selected as well as deeper pools. Naturally, the installation will vary depending on the options selected so it is important to understand exactly what has been supplied. When options are sent, installation instructions are included in the package. These instructions include information from the manufacturer when relevant, and a Supplemental Guide from Endless Pools, Inc. Each of the options is also discussed more fully in the Planning Guide which was used by the customer during discussions with the Endless Pools, Inc. design professional. Below is a summary description of the available finish options and important installation considerations. Please review this section before proceeding with the installation to ensure that selected options have been considered. Please note that if underwater lights or hydrotherapy jets have been selected, you should cut those holes in the pool panels at this time. More detailed installation information for the underwater lights and hydrotherapy jets can be found in Supplemental Guides. Additionally, the placement of the keypad needs to be considered. The majority of our customer's place the keypad on the front panel of the pool, which would require the hole be cut in the panel prior to installing the liner. However the keypad can be placed in the pool coping or the outside vertical finish. Please refer to the Keypad Section of these installation instructions for a more detailed description. 8

9 Optional Bullnose Coping System Typically used when the pool is installed fully in-ground, the Optional Bullnose Coping System allows the installer to finish with concrete and/or tile right up to the water s edge. The aluminum bullnose coping system acts as both a liner hanger and a finished edge. Endless Pools, Inc. supplies precut pieces to fit the specific pool size ordered. Included in the kit are radius corners and straight pieces to provide a finished look. These extrusions are fastened down to the top flange of the pool panels through the 1/8" PVC shims and the reinforcing channels in the same fashion as the regular liner hanger system. The installer is responsible for building a proper perimeter substrate for the concrete or tile. Optional Aluminum Coping System The Endless Pools Aluminum Coping Option offers a convenient method to finish off the top edge of your Endless Pool, either indoors or out. The coping, which also acts as a liner hanger, is 1- Securing aluminum coping system with tek screws. 3/8" thick and comes in a sand textured white finish. The pieces are precut to fit your pool size and fit securely over the steel channel. The coping system is delivered with your pool. It may be ordered Optional Bullnose coping system. Optional Wood Receiver Coping System Typically used when the pool is installed fully in-ground, the Optional Wood Receiver Coping System allows the installer to finish with wood or synthetic decking right up to the water s edge. The aluminum Wood Receiver Coping System acts as both a liner hanger and a finished edge which can easily accept 2" wood coping. Endless Pools, Inc. supplies precut pieces to fit the specific pool size ordered. Included in the kit are mitered corners and straight pieces to provide a finished look. These extrusions are fastened down to the top flange of the pool panels through the 1/8" PVC shims and the reinforcing channels in the same fashion as the regular liner hanger system. The installer is responsible for building a proper perimeter substrate for the decking material. Installing the aluminum coping snap strip. later and shipped by UPS ground for an additional shipping charge. The kit s weight depends on the pool size and comes in 5 boxes. Each coping kit contains pre-fabricated corners and straight aluminum pieces cut to match your pool size. The 8" wide profile of the Optional Wood Receiver coping system. Installing the aluminum cover strip. 9

10 coping makes it ideally suited for pools which are freestanding or partially recessed. The coping is secured to the top of the wall panel with tek screws, which are concealed beneath the aluminum snap strip of the same finish as the coping. As an alternative the 6-3/8" snap strip can be eliminated and a 6" accent tile can be installed. Joints between the adjacent coping pieces are covered with an aluminum cover strip with the same finish as the coping. 13. Liner Standard flat bottom pool liners are usually packaged in a cardboard box in the pool crate. Liners for deeper pools and custom-sized pools are sent separately by UPS Ground. Check to see if your liner was backordered at the time of shipment. If you have any questions call Customer Service about the status of your liner. 12. Foam Underlayment If it is possible, finish the rest of the pool area, especially the ceiling over the pool, before proceeding. This will help ensure that the liner is not damaged, and also keep the pool water, skimmer, and filter free of construction debris. Tape off all thru-wall holes and place vacuum hose through skimmer. Installing foam with spray adhesive. Vacuum the pool floor carefully, and make sure there are no sharp bumps that might damage the liner. Take special care to remove any metal chips that may have fallen on the floor. Install the protective foam underlayment on the floor of the pool. The foam kit comes in a box with the four foam corners and a can of spray adhesive. The foam is 3.5' x 32'. For wider pools cut pieces as appropriate to cover the floor of the pool. Place seams near the walls of the pool, so that they will be covered by the stainless steel benches. Secure the foam to the floor with the spray adhesive provided. With deeper pool installations and larger pools, a second and sometimes even a third box of foam has been provided. Secure the foam to the bottom and walls of the deeper area as well as to the floor of the pool. Do not attach foam to the steel walls of the pool. Secure the foam inserts in the 4 corners at the bottom. Foam corners are not installed in the 4 corners of the deeper section of a deeper pool. All work around your pool should be completed before you install your liner. Take a moment to be sure you have all necessary work completed. Prepare for the liner installation. Be sure that the liner hanger, corners, panel joints and panel to base material are sealed with silicone. Tape off all holes in the pool wall (lights, jets and front panel holes) from the outside. Place a vacuum hose through the skimmer hole and tape off the skimmer hole. The hose should be 3" 4" off of the bottom of the pool floor foam. Install the liner by starting at the center of the front panel. Spread the liner in the pool enclosure. Shoes should be removed for this and all future work in the pool to avoid damaging the liner. Find the vertical seam in the liner and center it at the front of the pool. Place the four bottom corners of the liner in the four corners of the pool. While standing in one corner, fit the top bead of the liner into Vacuum in place before liner is hung. Note thru-wall holes are sealed. Secure the foam corner inserts with spray adhesive. the slot in the liner hanger. Work your way around the pool, fitting the bead evenly into the hanger. We recommend not ending in a corner. Smooth the liner on the floor, pushing any wrinkles toward the walls. After verifying that the vacuum hose is off of the bottom, turn the vacuum on. When the liner is drawn back, check to see that the corners are positioned properly. If not, turn the vacuum off and reposi- 10

11 Spread out the liner inside the pool enclosure. tion the liner. With the vacuum running, smooth out all of the wrinkles. When you are satisfied with the placement of the liner, start to fill with water. Keep the vacuum running until there is about 6" of water in the shallowest portion of the pool. Turn the vacuum off and remove all tape and the vacuum hose. Slide the support beam into the front housing screw and discard. Extra screws have been provided. Please be aware, when securing 2 layers of benches to an internal PVC component the 1" screws should be used. When securing only 2 layers of benches, use the 3/4" screws. Attach the beam to the rear face of the front housing Inserting the liner in the corner of the liner hanger. Included in the box with the liner are No Diving signs. Please post these in prominent locations around the pool. The Endless Pool is shallow and must never be used for diving. Diving into the pool is a very serious hazard and these stickers are intended to warn children of the risks. Naturally, adult supervision is also critical whenever children use the pool. 14a. Cast Composite Bench The internal pool components can be found in four boxes inside the pool crate. There will be two bench boxes, each containing two benches and two intermediate side supports. There will be a width box containing the rear bench, the two base caps, two side supports, and the rear supports. There will be a front housing box containing the front housing, the four corner covers, the shroud, and the hardware kit. The support beam will be loose in the crate Please be aware that the boxes should not be open with a razor knife. If you have purchased a raised rear bench seat, please refer to its Supplemental Guide Keep the screws loose until you have started all the screws. You want to focus first on the bottom screws as they are difficult to work on once the holes are covered with water. If you use a cordless screw gun, take care not to over tighten the screws. Be careful to inspect for burrs while installing these screws. If a burr occurs remove the Remove the front propulsion housing from the pool crate. Lower the front housing assembly into the pool and position it in the center of the pool so that the front honeycomb grill is facing one of the long walls. Take care to keep the hose ends from getting wet. Two people can accomplish this if they work carefully in stages. Be careful not to catch the liner. There is a support beam for the rear of the front base that is side specific and will be labeled "L" and "R." A ten foot wide pool will have two side-specific support beams; they will be labeled "L" and Secure the front base face plate to the front housing. 11

12 Attach a corner turning vane to each side of the front base face plate. "R." Slide the support beam into the front housing so that the notch in the beam is facing up. The support beam should be positioned in the housing so that the notch is seated firmly against the front housing and is lining up with the holes in the rear of the front base. Use the 10/32 x 3/4" countersunk machine screws to attach the beam to the rear face of the front housing. It is advisable to secure the outer screw first. Be sure to push the beam firmly against the housing when securing. Carefully turn the assembly and slide it all the way to the front of the pool and make sure it is centered. Secure the front Position the top of the bench on a clean flat surface secure the bottom screw at this time. Use the #6 x 3/4" screws to secure the beam to the rear of each PVC corner support. Place the front right base cap in place. Secure the cap except for the 2 screws closest to the hole in the bench cap. Place the front left base cap in place an d thread the screws into the remaining holes in the front base. Now, peel off all the protective plastic from the side benches. The top of the bench is 12" wide and has two bends, while the vertical portion of the bench is 15" high and has only one bend. Position Instruction not listed? base face plate to the front housing. Start with the center screw, as this will force the rest of the holes to line up. Next, thread in the two screws immediately to the left and right of the center screw. Then thread in the two lower screws. Attach a PVC corner turning vane assembly to each side of the front base face plate. You only need to Attach the two holes that are directly left and right from the center hole first. the top of the bench on a clean flat surface so that the top surface is facing down and place the vertical face inside of the top piece and align the holes. Attach the two holes that are directly left and right from the center hole first. Make sure before tightening those two screws that the top and vertical pieces are flush on both ends. Place the base cap in place. Position the intermediate support on the inside of your bench 12

13 Secure one side bench to each of the front PVC turning vane assemblies. Position the intermediate support on the inside of your bench and align the two holes in the support with the two center holes on the vertical face. Simply repeat this process for the other three benches. Secure one side bench to each of the front PVC turning vane assemblies. Then, attach the PVC side support to the other end of the bench. Peel off all the protective plastic from the rear bench pieces. The top of the rear bench is 18-1/4" wide and the vertical portion of the rear bench has gray honey-comb grills. Position the top of the Position the top of the rear base on a clean flat surface so that the top surface is facing down. those screws that the top and vertical pieces are flush on both ends. Now take this unit that is secured together, position it so that the vertical face (with grills) is facing down on a clean flat surface. Position the two rear supports so that the holes in the top of the rear base align with the holes in the top of the rear support and secure. Carefully place the rear bench into the pool. Attach the other two PVC turning vane assemblies and slide the assembly all the way to the rear of the pool and make sure that it is centered. Place the remaining two side benches over the PVC turning vane assemblies Secure one side bench to each of the front PVC turning vane assemblies. rear base on a clean flat surface so that the top surface is facing down. Position the vertical face inside of the top piece and align the holes. Attach the vertical and top faces of the rear together by securing the screws through the provided holes. Make sure before tightening Attach the vertical and top faces of the rear together by securing the screws through the provided holes. and the PVC side support. Do not try to install the corner covers or any optional corner steps at this time. They may fit tightly against the liner in the corners and you risk cutting the liner. They should not be installed until more water is in the pool, which will push the liner back in the corners. Then, attach the PVC side support to the other end Position the two rear supports so that the holes in the top of the rear base align with the holes in the top of the rear support and secure. 13

14 Attach the other two PVC turning vane assemblies. Remove the top of the front propulsion housing by removing the six phillips head screws. Once all the bench screws are tight, secure the front housing back against the steel wall of the pool using the special corrosion resistant self-drilling fasteners. Make sure that steel bonding wire is securely fastened to one of the special corrosion resistant self-drilling fasteners prior to fully tightening, and then Place the shorter PVC angle onto the front right base cap. horizontal surface is facing up and the holes in the vertical face line up with back two screw holes for the housing top. Replace the screws. Once the Water Quality System has been installed (see Section 15 of this Instruction), place the shroud onto the housing so that it covers up both PVC angles and align with the holes in the angles. Secure with the provided 3/4" screws. Now that all the Remove the top of the front propulsion housing by removing the six phillips head screws. replace the top. Do not put the screws back in at this time. Place the shorter PVC angle onto the front right base cap so that the vertical face is facing out and the holes in the horizontal face line up with the holes in the base cap. Secure using the provided 3/4" screws. Place the longer PVC angle onto front housing so that the Place the longer PVC angle onto front housing. screws have been started into their proper holes, you can tighten them all down. Once all the screws have been tightened, continue to fill the pool. Stop filling three inches below the lowest thru-wall connection. Make sure that steel bonding wire is securely fastened to one of the special corrosion resistant self-drilling fasteners Place the shroud onto the housing so that it covers up both PVC angles 14

15 14b. Installation of Optional Stainless Steel Internal Components Do not try to install the stainless steel corner covers or any optional corner steps at this time. They may fit tightly against the liner in the corners and you risk cutting the liner. Put them aside for the moment. They should not be installed until more water is in the pool which will push the liner back in the corners. Once the stainless steel is in and the holes are lining up, you may continue filling the pool while you work. Stop filling three inches Attaching the front housing to the pool wall. Installing the side supports Remove the stainless steel front propulsion assembly from the pool crate. Attach the 2 PVC corner turning vane assemblies labeled Front Right and Front Left using the stainless steel 10/32 phillips head screws provided. These PVC turning vane assemblies are pre-drilled. Peel off all of the protective white plastic from the stainless steel. Lower the front propulsion assembly into the front of the pool taking care to keep the hose ends from getting wet. Two people can accomplish this if they work carefully in stages. Be careful not to catch the liner. Carefully slide the assembly all the way to the front of the pool and make sure it is centered left to right. Peel off all of the protective white plastic from the stainless steel side benches and install them inside the pool using the side supports at the junction between two benches. On the two benches at the rear of the pool include the Rear Left and Rear Right corner assemblies. below the lowest thru-wall connection. Once all the screws are tight, secure the front housing with the grab bar back against the steel wall of the pool using the special corrosion resistant self-drilling fasteners provided. Use only stainless steel, self drilling fasteners provided. Do not use Tek screws which will rust. Once the Water Quality System has been installed (see Section 15 of this Instruction), place the shroud onto the housing so that it covers up both PVC angles and align with the holes in the angles. 15.Water Quality System Once the water level is three inches below the lowest thru-wall, the holes must be cut in the liner for the return, both hydraulic hose assemblies, and any other thru-wall penetrations. Please refer to the Supplemental Guides for the hydrotherapy jets and/or underwater lights for instructions specific to those penetrations. Cut a round hole in the liner using the hole through the steel as a template. Please refer to the diagram on the next page for proper configuration of the fittings. The low pressure hose is the hose that leaves the base closest to the housing. We have provided two thru-wall fittings; the Attaching the 10/32" screw and nut. Peel off all of the protective white plastic from the stainless steel rear bench assembly with the perforated grill. Attach the rear base middle support to the perforated rear base using the two stainless steel 10/32 screws on top and one 10/32 stainless steel screw and nut provided with this plastic support. See Figure Lower this assembly into the rear of the pool as shown on the video. Keep all screws loose until you have started all the screws. Focus first on the bottom screws as they are difficult to work on once the holes are covered with water. If you use a cordless screw gun as shown on the video take care not to over tighten the screw into the PVC. Be careful to inspect for burrs while installing these screws. If a burr occurs remove the screw and discard. We have supplied extra screws. Water Quality System Components 15

16 Skimmer High Pressure Hose Optional Jet Suction Low Pressure Hose Return Fitting Install one rubber washer between the liner and the pool wall. Cut the thru-wall holes through the liner using the steel as a template. return fitting has a male slip x male threaded fitting pre-glued into it. The thru-wall fittings have two rubber gaskets and one cork gasket. One rubber gasket is placed between the liner and the pool panel. The other rubber gasket is placed between the fitting and the liner inside the pool. The cork gasket is placed outside the Install one rubber washer between the liner and the pool wall. Cut the liner using the skimmer opening in the panel as a template. pool under the large hex nut that holds the fitting to the pool wall. This nut should only be firmly hand tightened. Install the threaded plugs into each of the thru wall fittings to continue filling the pool. Repeat this process for both thru-wall fittings and the hydraulic hose assemblies. Fill the pool until the water level is 3 inches below the bottom of the skimmer opening. Cut the liner with a utility knife using the skimmer opening in the panel as a template. Punch the ten screw holes with a phillips head screwdriver. If you are going to place your keypad in the front panel, cut that hole in the liner at this time (see Keypad section for more information). Remove the faceplate, locking rear plate, and the gasket from the skimmer assembly. Place a small bead of silicone on the backside of the skimmer flange. Place the skimmer gasket on the backside of the skimmer flange making sure that the holes in the gasket line up with the holes in the flange. Place another bead of silicone on the backside of the gasket. Position the skimmer into the opening of the panel making sure to align the The low pressure hose is the hose that leaves the base closest to the housing. Position the skimmer into the opening of the panel. 16

17 Firmly thread the pump to the skimmer assembly union nut. holes in the skimmer with the holes in the panel. Secure the skimmer to the pool using the provided screws and locking rear plate. Snap on the skimmer faceplate. Close the ball valve. Place the pump gasket onto the face of the pump and firmly thread the pump to the skimmer assembly union nut. Teflon sealant is not needed for these Attach the support bracket directly to the panel Z-braces. board to line up with the holes in the heater. Tighten all four screws. Hold the heater in place and thread the pump heater connector onto the heater. You may need a helper for this step. When the heater is in place and level, attach the support bracket directly to the panel Z- braces using the provided tek screws. Firmly attach the pump heater connector to the pump. Reconnect the union half to the union half of the return assembly. threads. Make sure the discharge of the pump is facing the center of the panel. Firmly attach the pump heater connector to the pump. Now, attach the heater to the heater mounting board. The notch in the board should be facing down. Using the provided machine screws, loosely thread in the two top screws. Place the heater over top of these screws. This will force the lower holes in the mounting Unthread the union half from the return assembly. The return fitting comes with a pre-glued adapter. Add Teflon tape onto the male threads of the adapter and thread the union half, with union nut, onto the adapter. Loosely reconnect the union half on the return fitting to the union half of the return assembly. Make sure that the assembly is vertical. Hold the heater and thread the pump heater connector onto the heater. Take a measurement between the elbow and the heater union half. 17

18 make a mark on the return assembly stub pipe. Remove the return assembly from the pool and cut off the excess pipe at that mark. Now that both the flexible PVC pipe and the return assembly has been cut to fit, glue the pieces together. Glue the elbow onto the flexible PVC first. Make sure that the heater union is loose and then glue the elbow into the return assembly. Make sure that all threaded connections have been tightened. Once the pool is full, remove the threaded plug in the return fitting and install the eyeball fitting. Leave the plug in the alternate suction. Open both ball valves and check for leaks. If you find any leaks, please call Customer Service for assistance Make a mark on the return assembly stub pipe. Next, thread the heater union half onto the discharge of the heater. Loosely place the elbow onto the return assembly and make sure that it is facing the heater. DO NOT GLUE THE ELBOW ONTO THE RETURN ASSEMBLY! We have provided a length of flexible PVC pipe to make the connection between the return assembly and the heater. Take a measurement between the elbow and the 16. Keypad Additionally, the placement of the keypad needs to be considered. The majority of our customer's place the keypad on the front panel of the pool, which would require the hole be cut in the panel prior to installing the liner. However the keypad can be placed in the pool coping or the outside vertical finish. Feed the keypad, from the inside of the pool, through the cutout. When the flexible PVC pipe and the return assembly has been cut to fit, glue the pieces together. heater union half. Make sure that the socket depth of both the elbow and the heater union are taken into account. Cut the provided flexible PVC to that measurement. Glue the PVC pipe into the heater union. Make sure that you use the PVC cleaner on both faces of the glue joints before applying the PVC glue. Remove the elbow from the return assembly. Make sure that the PVC pipe is level and When installing the keypad in the front panel, it is important to keep it above the water line, 1-1/2" down from the top flange is an ideal level. At that level, drill to 1" diameter holes at 2-5/8" from center to center. Please refer to page 3 of the Water Quality Supplemental Guide. When deciding on placement of the keypad is to important to make sure that the z-braces on the back side of the front panel are not in the way. Once the hole is cut in the panel and the liner is in place, cut the liner for the keypad hole at the same time you cut the hole for the skimmer (see Water Quality System Section). You can use the hole in the panel as your template. Completed water quality system. Thread the two wing nuts over the threaded studs and hand tighten them. 18

19 First, peal of the adhesive protection on the backside of the keypad. Feed the keypad cord, from the inside of the pool, through the cutout. Firmly press the keypad into place. Then, feed the bracket through the cord and push the bracket all the way up to the panel. Make sure that the bracket is placed over the two threaded studs on the back of the keypad. Once that is completed, thread the two wing nuts over the threaded studs and hand tighten them. If you are going to have your keypad in a horizontal surface, then simply cut your holes, remove the adhesive protection, feed the cord into the hole, and firmly press the keypad into place. When picking a location for the keypad in your finish work, it is important to take into account the length of the keypad cord. wire to R3 on the load (right) side of the contactor, connect the green wire to the ground bus bar, and the white wire junctions with the white wire coming from the shut off using a wire nut. Connect the heater controller by attaching the black wire to the L1 terminal, the red wire to the L2 terminal, the white wire to the N terminal, and the green wire to the G terminal. Now that the Water Quality System has been installed and your electricain has completed the wiring, you should install the Water Quality System Cover. Place the cover over the entire water quality system. Use the provided self-tapping screws to attach the cover to two of the Z-braces. It is important to keep it above the water line. Water Quality System Cover 17.Wiring One 220 volt 30 amp GFCI circuit is all that is required to operate the Endless Pool. A minimum of 10AWG wire should be used for all field wiring. All connections should be made by a licensed electrician. We recommend that you have your electrician install a shut off within 5' of where you intend to place your power unit. You can have your electrician install this prior to your pool being delivered. Typical power supply configuration Power is supplied to the system by connecting the existing whip on the power unit control box to the shut off installed by your electrician. Power the pool-side heater controller by connecting the whip supplied to both the power unit control box and the heater-controller through the appropriate knockouts in these respective units. Specifically, inside the power unit control box, connect the black wire to terminal R2 on the line (left) side of the contactor, connect the red 18. Power Unit The power unit should placed on flat and level surface. If the power unit is to be placed outside, we recommend selecting our Outdoor Power Unit with Weather Guard to protect it against everyday elements. Whether placed indoors or outdoors, this is an air-cooled unit and must have ample ventilation. Therefore, a minimum of 12" of air spaced must be provided on all sides of the power unit. In addition, the power unit needs to be check periodically for maintenance and should be accessible. The power unit is heavy, care should be taken when placing the power unit. Once the power unit is in place, connect the run hoses. The low pressure hose, which is connected to the lowest hydraulic hose on the front panel, gets connected to the connection on the black fill cap. The high pressure hose gets connected to the fitting on the high pressure manifold. Make sure that the power is turned off to the power unit. Remove the fill black fill cap and remove the oil filter by lifting it out of fill opening. Use the provided paper funnels and fill the reservoir to with in 2" of the top. Once filled, replace the oil filter and ensure that it is seated properly before putting the fill cap back on. If you have selected a longer run hose, we have provided extra fluid. In this case, turn the unit on and let it run for one minute to fill the run hoses. Turn the power off, remove the fill cap and oil filter, and add fluid as needed. Again, you want to fill the reservoir to within 2" of the top. The power unit controller comes equipped with an automatic timer shutting off the system 30 minutes after receiving its last command. Because the controller "remembers" the last speed at which is turned off, it will return to that same pace when it is turned back on. 19

20 Optional Antenna Extension Your swim current remote operates by radio waves. Should the power unit be placed far away from your pool, the remote control may not operate efficiently. In order to correct this, you should install the Antenna Extension Kit. Please call Customer Service with any questions. If your antenna has already been installed, disconnect it from the side of control box. Install the antenna extension wire finger tight onto the control box connection. Once the antenna has been positioned closer to the pool, connect the other end of the extension wire to the antenna. Should you need a longer wire than what was provided, you can purchase coaxial cable locally. Low Pressure Fitting High Pressure Fitting 19. Bonding and Grounding All of the electrical equipment that we supply is UL or CSA approved and must be installed in accordance with local electric codes by a licensed local electrician. Bonding and Grounding is an important part of that process. All electrical components have bonding lugs and should be bonded together and to the steel pool panels. A bonding conductor shall be solid copper not smaller than 8 AWG and may be insulated, covered or bare. If new construction is involved where reinforcing rods are installed in the concrete under or adjacent to the pool this should be included in the bonding circuit. Each of the pieces of equipment should be separately grounded. 20. Hydraulic Fluid Fill the reservoir on the Power Unit no more than 2" from the top of the reservoir. Endless Pools, Inc. supplies a special non-petroleum fluid created for this application and this equipment. Do not use a substitute hydraulic fluid. Extra hydraulic fluid is provided for longer hose runs. Any excess fluid should be retained for future use. Make sure that all hydraulic connections are tight, then press the ON button on the remote to turn on the Power Unit. Run for a minute or two then check for hydraulic leaks at the Power Unit and the pool and tighten if necessary. By pressing the OFF button on the remote you can turn off the Power Unit. Make sure you can do this. All of the electrical equipment that we supply is UL or CSA approved and must be installed in accordance with local electric codes by a licensed local electrician. Bonding and Grounding is an important part of that process. All electrical components have bonding lugs and should be bonded together and to the steel pool panels. A bonding conductor shall be solid copper not smaller than 8 AWG and may be insulated, covered or bare. If new construction is Hydraulic hoses are installed on the power unit.the fitting on the filter/fill cap is the low pressure fitting. involved where reinforcing rods are installed in the concrete under or adjacent to the pool this should be included in the bonding circuit. Each of the pieces of equipment should be separately grounded. 21. Hydraulic Hose Connections Fill Cap Adapter to make these connection to run hose. Fig 39.1: Power Unit fill cap is located above the low pressure fitting. Install the long hydraulic hoses between the Power Unit and hydraulic hoses at the front of the pool. These hoses are supplied by Endless Pools, Inc. to the length specified. Often they are not shipped with the pool as the exact length is unknown at the time of shipment. Please order these hoses a week before they are needed to allow shipment by UPS ground. Two hoses up to 25 feet in length are supplied at no additional charge. It is best to use hoses close to the length you need rather than simply going with the standard 25 feet. Lengths in excess of 25 feet cost $5 per foot, e.g. two 40 foot hoses cost 15 feet x $5 = $75. Remove the protective plugs and connect the 2 hydraulic hoses to the 2 ports on the Power Unit and tighten firmly. Do not over-tighten. The hose connecting to the fill cap on the Power Unit is the return (low pressure) hose, which gets connected to the lowest hydraulic hose at the front panel. The high pressure hose, which is connected to the fitting on blue high pressure manifold, connects to the higher hose at the front of the pool. The hoses that go through the panels are a smaller diameter than your run hose, you will find adapter in theelectrical Whip box to make these connections. If the hoses you ordered are too short and you need longer hoses, call Customer Service. Extra care should be taken that these hoses are cushioned when they pass by anything that could reverberate. This will ensure a quieter installation. Use simple pipe insulation and clips for this purpose. 20

21 Final hydraulic hose connections. 22. Optional Retractable Security Cover Systems Our most popular option and strongly recommended, the Retractable Security Cover system protects children and pets from the pool while keeping in temperature and humidity. With some installations, suitable access for this roll up cover system is complex and should be discussed with an Endless Pool design professional during the planning stage. Supplemental Guide describes the cover installation more fully. If your pool is to be outside, we can provide you with a cover pump to remove any rain water that may accumulate. The most popular configuration for this system is to have the cover roll off the rear of the pool. Other alternatives are possible if space is limited. These are discussed in more detail in the Supplemental Guide. The kit includes the roller mechanism for the width of pool purchased, appropriate lengths of track, an aluminum leading edge, and the rugged fabric which floats on the water surface suspended between the parallel tracks. Two steel brackets to mount the roller mechanism at one end of the pool are available. The optional Retractable Security Cover system is manually powered. We believe that this system is optimal for our compact pool and when installed correctly provides a simple means of covering the pool. The aluminum track on either side of the pool is a requirement of the retractable security cover option. Covering this track is possible but increases complexity and will add to the cost of installation. Call Customer Service for details. Optional Automatic Retractable Security Cover System Offered in two versions, the Automatic Retractable Security Cover System is rapidly becoming one of our most popular options. Operated with the turn of the key, the cover retracts easily making it ideal for people want the convenience of automation or lack the strength to operate one manually. The Below Deck version can be fully integrated into any custom finish. The cover mechanism must be mounted at the front of the pool. Please refer to the Supplemental for more information on this option. The Above Deck can mounted at either the front or the back of the pool and is compatible with any of our coping options. The Above Deck version comes with a convenient bench cover offered in a variety of colors to compliment any decor. Please refer to the Supplemental Guide for more information on this option. Optional Solar Blanket Roll Up System Endless Pools, Inc. supplies an Solar Blanket for all Endless Pool sizes, if the Retractable Security Cover has not been chosen. For those who wish it to serve as a permanent cover, a simple PVC pipe may be used to roll up the blanket for storage when the pool is in use. For this purpose, we supply PVC clips and PVC pipe long enough for your pool width. Depending on the width of the pool the PVC pipe will come in one or two pieces with a coupling attached to one end of the one piece of pipe. Using the PVC cleaner and PVC cement you received in your plumbing kit, glue the second piece of pipe into the open end of the coupling. Alternatively, the roller mechanism from the retractable security cover may be used in conjunction with a length of 3" diameter PVC pipe to roll up the blanket. This optional solar blanket roll up system is available from the Endless Pools, Inc. Customer Service Department. 23. Optional Hydrotherapy Jets System By providing a supplementary pump that is operated by the heater controller and using the secondary suction and four venturi-type jets through the wall of an Endless Pool, the user can enjoy the therapy benefits of jets in addition to the variable speed swim current. Installation is relatively straightforward but roughly doubles the plumbing work required. The kit provided by Endless Pools Inc, includes everything necessary with the exception of the 1-1/2" schedule 40 PVC pipe. Detailed instructions are included in the Supplemental Guide along with a typical layout drawing. When jets are installed it is important to leave access to the outside of the pool panel for service. The five holes for the jets should be cut before installing the liner. If the pool is located outdoors where freezing is an issue, care must be taken with the jet system plumbing. Additional insulation should be considered under these conditions. Call Customer Service with any questions about this limitation. 24. Optional Underwater Lights System Underwater Lights are an important aesthetic option. Typically located on either the side or the end wall of the pool, these two lights thread into in niches that are installed after the liner is in place. The holes for these niches are cut using the holesaw provided before the foam and the liner are installed. Directions come with the lights which are packaged in the pool crate. These directions are also found in the Supplemental Guide. Each light consists of a dry niche which serves as a porthole. The low-voltage light threads into this porthole outside the pool. For outdoor installations a weather resistant can is provided for added protection. A 22' cord connects these lights plug directly into the the heater controller and are then operated by the pool-side controls. 25. Optional Corner Step To assist with access to the Endless Pool, optional Corner Steps are available inside the Endless Pool in any of the four corners. For a more complete discussion of access to an Endless Pool please refer to the Planning Guide. These optional steps are approximately 11" high and are secured to the internal bench/water return system. They are easily installed using a phillips screwdriver. If you wish to order them after the pool has shipped, contact the Customer Service Department and they will ship one to the address provided. The optional Corner Step is described more fully in the Supplemental Guide. 21

22 26. Optional Full Depth Stair For those needing an easier route into the pool our optional Full Depth Stair provides seven low-rise steps and a handrail. Typically installed with fully in-ground Endless Pools, the Full Depth Stair allows the user to gradually enter the water from deck height. The steps do not obstruct the swim current. The Full Depth Stair takes the swimmer down to the bottom of the benches. If an optional deeper pool has been selected, you would step from the bottom of the stair down into the deeper area. Care must be taken to ensure that the shelf on which the Full Depth Stair rests is sufficiently large. The shelf must extend 60" from the end wall where the steps are located. Details of this design should be worked out in advance with an Endless Pools design professional. The optional Full Depth Stair is described more fully in the Supplemental Guide. The Full Depth stair should be ordered with the pool to avoid substantial additional freight charges due to the size and weight of the box needed to ship the steps. 27. Optional Swim Mirror The Swim Mirror helps with stroke technique and makes your swimming workout fun. The Swim Mirror, described more fully in the Supplemental Guide, is made from durable stainless steel and is attached with three stainless steel screws which are already attached to the housing just below the swim propulsion housing. When a deeper pool is selected, make sure that the shallower area extends at least 13" beyond the front bench to accommodate the Swim Mirror. Swim Mirrors are easily sent by UPS ground and may be ordered later. Optional Synthetic Coping System An ideal solution for indoor installations, the Synthetic Coping System finishes off an Endless Pool quickly and easily. Typically used when the pool is installed partially or fully aboveground, the Optional Synthetic Coping System provides a finished 9-3/4 wide waterproof edge to your pool. Made of synthetic boards and corner pieces with shiplapped joints, the system comes in a variety of colors. Please refer to Supplemental Guide for additional installation information. Fig 13.1: Synthetic coping system. (Sandstone shown) 22