®

INDUSTRIES,INC.

QUICK-START
INSTALLATION MANUAL
FOR USE WITH:

EAGLE CLAW™ MOUNTING SYSTEM

•SAVE INSTALLATION TIME AND AVOID CALL-BACKS•

•READ THIS MANUAL BEFORE MOUNTING COLLECTORS•

MANUAL CONTENTS CAUTION: SOLAR COLLECTORS ARE OFTEN

INSTALLED ON THE ROOFS OF BUILDINGS. UN-
This manual provides a detailed step-by-step pro- LESS YOU ARE VERY FAMILIAR WITH WORKING
ON ROOFS AND HAVE THE PROPER LADDERS
cedure for the installation of an Aquatherm Indus-
AND SAFETY EQUIPMENT FOR SUCH WORK,
tries Solar Pool Heating System. If the directions YOU SHOULD HIRE SOMEONE WITH THE NEC-
are followed correctly and only recommended Aq- ESSARY EXPERIENCE TO DO THE INSTALLA-
uatherm Industries hardware and components are TION. FAILURE TO OBSERVE SAFE PRACTICES
used, the installed system should provide years of ON A ROOF OR OTHER ELEVATED STRUCTURE
MAY RESULT IN FALLING, LEADING TO SERI-
trouble free service, savings, and enjoyment.
OUS INJURY TO YOU.
Product Guide

Figure 1: Installation Kits

Collector Installation Kit 4 Add-a-Row Kit

1
(PN 12034-1 for 1½”; PN 12034-2 for 2”) (PN 12043-1 for 1½”; PN 12043-2 for 2”)
Contains the parts needed to fasten a single solar collector Used when more than one row of collectors is to be in-
to a supporting surface and make water connections from stalled. The kit contains additional hold-down hardware, con-
one collector to another. Hold-Down Strap is not included nector hoses, and adapters. Use one (1) kit for each row
and must be ordered separately. One (1) kit required per of collectors after the first.
collector.
5 Row Spacer Kit
2 System Installation Kit (PN 12017-1 for 1½”; PN 12017-2 for 2”)
(PN 12135-1 for 1½”; PN 12135-2 for 2”) Contains the hardware needed to space around any width
Includes additional hold-down hardware, connector hoses, obstruction by connecting appropriate lengths of PVC pipe
and adapters needed to complete water connections from to the Pipe Adapters at the inlet and outlet headers of the
collectors to the system feed and return line. One (1) kit re- two collectors on either side of the obstructions. Use one (1)
quired per system. for each gap between collectors.
Supplemental Outlet Header Clamp Assemblies
2A Optional Supplemental System Isolation Kit 6
Used as supplemental outlet header mounting in conjunc-
(PN 12033-5) - Permits manual isolation of the solar sys-
tion with the Outlet Header Hold-Down Bracket Assembly.
tem from the pool or spa filtration system. Includes a 1½” -
Designed for installations that require more flexibility for the
2” PVC union ball valve and a 1½” - 2” PVC check valve.
outlet header mounting hardware location, such as barrel tile
Use (1) kit per system.
roofs or installations that require additional mounting hard-
3 Hold-Down Strap ware to be anchored into rafters or beams..
(PN 12033-5) - Required to secure collectors to the mount- Use up to two (2) per collector.
ing surface. Use 54’ roll (PN 10035-1) for rows of up to six
(6) collectors with two straps. Also available in 107’ roll for
rows up to twelve (12) collectors (PN 10035-2), and bulk
1400’ roll (PN 10040).
PN 10117-1 / -2 PN 10121

2 1
Product Guide
Connections & Hardware

Outlet Header Hold-Down Flashing Base, Hold-Down Flashing Base,

Bracket Assembly Outlet Header Strap Bracket Strap Bracket
(PN 10008-1, -2) (PN 30340-1) (PN 50006) (PN 30340-2)

Double Hole Outlet Hold-Down Strap Stainless Steel Vacuum-Relief

End Cap
Header Bracket Clamp Assembly Hose Clamp Valve
(PN 50069) (PN 10011) (PN 60003-1, -2) (PN 30061-1, -2) (PN 10003-1, -2)

Collector Connector Hose System Connector Hose Pipe Adapter

Check Valve
(3 3/4” long) (7” long) (High-temperature CPVC)
(PN 60690-1, -2) (PN 60691-1, -2) (PN 30089-1, -2) (PN 60019-2)

Colle
ector Systtem
Row Spacer Kit Add-a-R
Row Kit
Installation Kit Installation Kit
(PN 1201
17-1, -2) (PN 1204
43-1, -2)
(PN 1203
34-1 / -2) (PN 1213
35-1, -2)

1½” 2” 1½” 2” 1½” 2” 1½” 2”

10008-1, -2 Outlet Header Hold-Down Bracket Assembly 1 1 1 1 1 1 1 1

30340-1 Flashing Base, Outlet Header 1 1 1 1 1 1 1 1

50006 Hold-Down Strap Bracket 2 2 2 2 2 2 2 2

30340-2 Flashing Base, Strap Bracket 2 2 - - - - - -

10011 Hold-Down Strap Clamp Assembly - - 4 4 4 4 4 4

60003-1, -2 Hose Clamp, Stainless Steel 4 4 4 4 4 4 4 4

30061-1, -2 End Cap - - 1 1 - - 1 1

10003-1, -2 Vacuum Relief Valve - - 1 1 - - 1 1

60690-1, -2 Collector Connector Hose (3 3/4” long) 2 2 - - 2 2 - -

60691-1, -2 System Connector Hose (7” long) - - 2 2 - - 2 2

30089-1, -2 Pipe Adapter (high-temperature CPVC) - - 2 2 4 4 2 2

60019-2 Check Valve (1½” & 2”) - - 1 1 - - - -

19001 Installation Manual - - 1 1 - - - -

19697 Owner’s Manual - - 1 1 - - - -

3 2
 Figure 2: System Schematic

4
Mounting the Collectors
Collector Layout Overview & Planning for Obstructions
weld while pulling the two plates apart. Lay the collector
over the vent pipe, keeping the vent pipe at least 12
inches (30cm) away from a header. It will be easier to
complete an installation by mounting this panel first and
then working away from it.

For obstructions up to 7” (18cm) in diameter, the

collectors can be positioned on either side of the vent.
Two 7” (18cm) long System Connector Hoses (PN
Overview 60691-1 for 1½” or PN 60691-2 for 2”) can be employed
to couple the collectors together for vent pipes or other
• When mounting the collectors, always make provi- obstacles up to 7” (18cm) in diameter. Mark your 51”
sions for inlet connections at the bottom header and (128cm) centers wherever the outlet header brackets
outlet connections at the top.
‘fall’ on the upper chalk line.

• The outlet headers must be pitched a vertical dis-

For obstructions over 7” (18cm) in diameter, such
tance of at least 1/8” per foot (1cm per m) above the
inlet headers to assure uniform flow and proper drain- as attic fans and skylights, position collectors on either
age to prevent freezing. side of the obstruction using a Row Spacer Kit (PN
12017-1 for 1½”; PN 12017-2 for 2”) or Header Spacers
• Plan system location to allow at least 12” (30cm) on (PN 30017-1, 2, 3, 4 for 1½”; 30159-1, 2, 3, 4).
all sides of the row(s) of collectors for mounting brack-
ets and piping.

Roof obstructions, if present, should now be taken

into account to determine the exact collector location.

Collectors can be installed over or around different di-

ameter roof vent pipes or other obstructions. After snap-
ping the top chalk lines but before marking and pre-
drilling for your outlet header brackets, refer to the fol-
lowing instructions:

For roof vents up to 2” (50mm) in diameter the col-

Using various configurations of hoses and header
lectors can be installed directly over these vents. Locate
spacers, this system avoids roof obstructions
the seam in the panel nearest to where the vent pipe is
while maximizing the solar collector area. (Photo
to come through. Separate by pulling up on top plate,
courtesy of Solar Living - Fair Lawn, NJ)
and pushing down on the lower plate. Should the vent
pipe protrude near a sonic tack weld, it will have to be
cut apart. Using a sharp utility knife, cut through the

5 2
Mounting the Collectors
Step 1: Install Outlet Header Hold-Down Bracket Assembly
1. Determine the position of the last Outlet Header Hold-Down Bracket As-
sembly for the row of collectors, and mark this point on the roof. The col-
lector outlet headers will be located 1” (25mm) below this mark.

2. Using this point, snap a chalk line to the opposite end of the row. Slope
this line down the roof toward the inlet a minimum of 1/8” per foot
(1cm per m).

3. Using a 1/8” (3mm) drill bit (for 1/4” (6mm) diameter screws), drill a pilot
hole for the first Outlet Header Hold-Down Bracket Assembly on the first
roof mark.

4. Measure up 1” (25mm) on center from the first pilot hole and drill a pilot
hole for the second screw. Repeat this process all along the chalk line
for the total number of collectors to be installed.

5. Inject a generous amount of high quality sealant into each hole and onto
the surrounding roof surface. Attach the Flashing Base & Outlet Header
Hold-Down Bracket Assembly to the roof as shown in Figure 3.
FIGURE 3

Step 2: Hold-Down Strap Bracket Locations

1. Locate the Hold-Down Strap Bracket (PN 50006) locations using Table 1 below. Measure “(A) Distance” down from
the top Outlet Header Bracket, and snap a chalk line to the opposite end of the row. If using the Optional Supple-
mental High Wind Area Collector Hold-down Kit, use (A2) Distance from the outlet header for all three top straps

2. The “(B) Distance” can be measured after the collectors are installed, and is the same for all collector sizes: 16”
(40cm) up from the bottom of the inlet header.

Wait to install the Hold-Down Strap Brackets until after collectors are installed, so as not to
damage the collectors when you are bringing them to the roof for installation.

T ABLE 1 DISTANCE BETWEEN COLLECTOR HEADERS AND STRAPS

Collector Panel Size, Feet (m) 12 (3.6) 10 (3.0) 8 (2.4) 6 (1.8) 4 (1.2)

(A) Distance from Outlet Header, Inches (cm) 60 (152) 48 (122) 36 (91) 24 (60) -

(A2) Distance from Outlet Header, Inches (cm) 32 (81) 28 (71) 20 (51) - -

(B) Distance from Inlet Header, Inches (cm) 16 (40) 16 (40) 16 (40) 16 (40) 16 (40)

6 3
Mounting the Collectors
Step 3: Install Connection Hoses on Collectors
Make sure that the header with the serial number label is used for the outlet or top header.
The serial number label must face downwards towards the mounting surface.

1. Bring the first collector to the roof and slip the proper hoses over both ends of the inlet and outlet headers on the
last return collector.

2. Use System Connector Hoses (PN 60691-1 for 1½”; PN 60691-2 for 2”), at the system’s feed and return points
(outlet of the last collector and the inlet of the first collector).

3. Place a hose clamp between the two indicator ridges on the hose, in order to center it over the sealing groove in
the header. This clamp must face up so as to be accessible for tightening and not rub against the mounting sur-
face.

4. Make sure you securely tighten each clamp with a nut driver. If a nut driver is not available, a ‘hex’ wrench or
screwdriver will suffice.

The hose clamps must be located between the two indicator ridges on the hose.
Do not tighten more than 35-40 inch-pounds!

Step 4: Secure Outlet Header Bracket to Collector Connector Hoses

1. Position the collector on the roof so that the center of the outlet Con-
nector Hoses are directly beneath the secured Outlet Header Hold-
Down Brackets.

2. Open the clamp that is part of the outlet header bracket, insert con-
nection hose and lightly tighten the clamp around the hose.

3. Loosely place another clamp over the open end of the hose before
installing the next collector in the array. Refer to Figure 4.

4. Continue to install all the collectors in the array, coupling them side
to side. FIGURE 4

Supplemental Mounting Hardware

If using the supplemental Aluminum Header Clamp Assembly,
(PN 10117-1 for 1½”; PN 10117-2 for 2”), or GFPP Outlet
Header Clamp Assembly, (PN 10121) install after both the Outlet
Header Hold-Down Brackets and collectors have been installed.

7 4
Mounting the Collectors
Step 5: Install Hold-Down Strap Brackets & Stainless Steel Strap

1. At the lower chalk line previously snapped on the roof, mark locations for
the first row of Hold-Down Strap Brackets 2” (5cm) away from the first and
last collectors and centered between each collector.

2. Drill a pilot hole and apply sealant, then mount the Flashing Base and
Hold-Down Strap Bracket. Slip a Strap Hold-Down Clamp (PN 10011) over
the end of the strap prior to pulling it through (refer to Figure 5).

3. Loop approx. 2” of strap through the Outlet Header Bracket and then back
through the Hold-Down Strap Clamp. Slide the Hold-Down Strap Clamp
towards the Hold-Down Strap Bracket. The screw should be tightened se-
curely, but not over-tightened to the point where the clamp is distorted (re-
fer to Figure 5). FIGURE 5

For longer arrays it will be easier to start the strap

in the middle collectors and work your way out.

4. Moving across the row, drill pilot holes at each marked point between collectors, apply sealant, and attached all
Flashing Bases and Hold-Down Strap Brackets to the roof.

5. Bring the remaining strap end across the collector face, passing through both
slots of the Hold-down Strap Brackets between collectors. Pull strap taut
against the face of the collectors. Repeat strap termination at opposite end
(refer to Figure 6).

6. Mark, drill, and mount the remaining Hold-Down Strap(s) by repeating the
above steps at the distance(s) specified in Table 1 in Step 2: Hold-Down
Strap Bracket Locations.

It is ok to step on the collectors, as long as you stay

one foot away from the top and bottom headers.

FIGURE 6

8 5
Mounting the Collectors
Step 6: Install Vacuum Relief Valve & End Cap
1. Install the Vacuum Relief Valve (PN 10003-1 for 1½”; PN 10003-2 for 2”) in the
outlet header of each row.

This will be located at the opposite end of the header that is connected to the
collector return line.
Vacuum Relief Valve

2. Install an End Cap (PN 30061-1 for 1½”; PN 30061-2 for 2”) in the inlet header of
each row, opposite the end that is connected to the collector inlet pipe.

Do not over-tighten hose clamp around VRV or End Cap

End Cap

Installation in High Wind Areas

In regions where high winds are prevalent, use the Supplemental High Wind Area Collector Installation Kit, (PN 12035-1
for 1½”; PN 12035-2 for 2”) and Supplemental Row/System Kit (PN 12143-1 for 1½”; PN 12143-2 for 2”) in addition to
the standard installation kits (refer to Figure 7). The included bracket assembly’s spring-tension design allows for
collector expansion and contraction, while providing an additional mounting point. Supplemental High Wind Kits also
contain the required hardware for two additional Hold-down Straps. Use Table 2 below to determine proper spring-
tension length, based on collector size and average air temperature.
FIGURE 7
T ABLE 2 SPRING TENSION LENGTH High Wind Area Hold-down Kit

TEMP 8’ 10’ 12’

0
5”
5
15 5”
5”
5
30

45
4 3/4
4- 3/4”
60

77 4- 3/4”
4 3/4
4- 3/4”
85

100
4 1/2
4- 1/2”
115

130 4- 1/2” 4- 1/2”

145
4 3/8
4- 3/8”
160 4- 3/8” 4- 3/8” NOTE: Bracket not at tension

9 6
System Piping
Overview
Piping to and from the collectors should be the same type of plastic piping and fittings approved for use with swimming
pool filters and pumps. It is recommended to always use Schedule 40 PVC pipe and fittings.

Whenever there is more than 50 gpm (189 Lpm) required flow rate to the collectors or more than 100’ (30m) of piping
used in a system, install 2” (63mm) piping to and from the collectors. See Table 3 for Pipe Size Based on Flow Rate.

T ABLE 3: PIPE SIZE BY SYSTEM FLOW RATE

UM FLOW TO PURG
MINIMU GE AIR SUPPORT CENTERS
MINIMUM PIPE
FLOW RATE SIZE @ 7 FT/S HORIZONTAL FOR HOR
RIZONTAL
FLOW-UP DOWN FLOW
(GPM) VELOCITY FLOW PVC PIPE (FE
EET) @100ºF
(INCHES)
2 FT/S 4 FT/S 6 FT/S SDR&SCH. 40 SCH. 80

50 1.5 11 22 33 5.0 5.5

80 2.0 20 39 59 5.0 6.0

115 2.5 31 61 92 5.5 6.5

160 3.0 44 88 132 6.0 7.0

300 4.0 78 157 235 6.5 7.5

650 6.0 176 353 529 7.5 9.0

1050 8.0 300 650 1000 8.0 8.5

• If a fuel-fired heater or heat pump is installed, it should be located between the solar return line and the return line
to the pool.

• Although PVC pipe is generally white, black is also available but may be difficult to find locally. If black pipe is
desired for aesthetics, it can always be painted black. Before painting, the PVC pipe must be wiped with cleaner to
remove the glossy surface coating. This will ensure that the paint will not flake off prematurely.

• Use a PVC cutter or a PVC wide-blade saw (not a hacksaw) for cutting pipe. It is important to use both a quality
cleaner/primer and solvent in gluing a PVC joint. Finally, use a cloth while either gluing or painting to keep the job a
clean one.
Pipe Brackets
• Piping should also be supported at intervals based on pipe size
(see Table 3). Aquatherm Industries Pipe Brackets made from
high-strength glass-reinforced polypropylene are available in
1½” (PN 30272-1 black; PN 30284-1 white) and 2” (PN 30272-2
black; PN 30284-2 white).

10 7
System Piping
System Piping Configurations
The most common piping configurations use a pressure filter. The pump draws the water from the skimmer and/or a
main drain, forcing it through the filter and sending it back to the pool through the return lines. (For other types please
contact Aquatherm’s Engineering Department).

FIGURE 8 FIGURE 9

Reverse Return Direct Return

In a traditional reverse return piping configuration, In certain situations, it may be desirable to
the feed and return points of each row of collec- configure a system with the feed and return points on
tors will be diagonally opposite each other. the same side of a row of collectors (see diagram to
left).
The Vacuum Relief Valve and End Cap of each row
will also be diagonally opposite each other (see dia- Though this configuration reduces the total pipe re-
gram at right). quired, and is often more aesthetically-pleasing,
proper flow rates are crucial to ensure balanced flow
Using a reverse return configuration ensures through each row.
balanced flow across the entire row of collectors.
See Table 4 below to determine the maximum num-
ber of collectors allowable in a direct return system at
various flow rates.

T ABLE 4: REQUIRED FLOW FOR DIRECT RETURN

8’’ 10
0’ 12
2’
COLLECTOR SIZE:
1½” 2” 1½” 2” 1½” 2”

MINIMUM FLOW RATE (0.06 GPM/FT²) - - - - - -

STANDARD FLOW RATE, (0.10 GPM/FT²) 6 6 6 6 6 6

RECOMMENDED FLOW RATE, (0.15 GPM/FT²) 7 8 7 8 7 7

MAXIMUM FLOW RATE, (10 GPM PER COLLECTOR) 8 12 8 10 8 8

11 8
System Piping
Flow Rate
In order to achieve optimum performance from Aquatherm Industries
collectors, the recommended flow rates and number of collectors per
row in Table 5 should be followed.

When the system is running, all the collectors should feel uniformly cool
to the touch, and there should be no residual air left in the pool return
lines. If collectors feel warm or hot to the touch, or air bubbles in the
return line persist, chances are that flow through the collectors is
inadequate or the system is not properly balanced (refer to the section
concerning the Vacuum Relief Valve Test on page 14.

• A flow meter can be installed in the collector feed line to check the flow rate. If the flow rates are within the limits as
shown above in Table 5, the system may not be properly balanced, especially in systems with multiple banks of
collectors.

T ABLE 5: FLOW RATES

COLLECTOR SIZE, FEET: 4 X 12 4 X 10 4X8

STANDARD FLOW RATE PER COLLECTOR, GPM (LPM) 5.0 (18.9) 4.0 (15.1) 3.25 (12.5)

MINIMUM FLOW RATE PER COLLECTOR, GPM (LPM) 3.0 (11.4) 2.5 (9.5) 2.5 (9.5)

MAXIMUM # COLLECTORS PER ROW, 1½”; 2” 10; 12 12; 12 12; 14

MAXIMUM SQUARE FOOTAGE PER ARRAY, 1½”; 2” 480; 576 480; 576 480; 576

PRESSURE DROP (PSI @ GPM):  1½” - 0.05 @ 2.5; 0.13 @ 5.0; 0.39 @ 10.0
      2” - 0.05 @ 2.5; 0.20 @ 5.0; 0.60 @ 10.0

If the flow rate is below the minimum as shown in the table above, then the pool pump size or
pipe size should be increased, or a booster pump installed in some cases.

If the flow rate is excessive (more than 10 gpm / 37.9 Lpm) collector), or if the system pressure
is greater than 30 psi, a By-pass Check-Valve (PN 60717) should be installed between the
collector feed and return lines above the 3-way valve to prevent problems with the collectors
and connection hoses.

If the system has been installed according to this manual, optimum performance conditions will now exist. Systems
with rows of collectors of unequal size, but fitted with balancing valves, may now be adjusted.

Open all balancing valves completely and let the system run for several minutes. Any row that is warmer to the touch
than others is currently receiving less flow then it should for optimum performance. Throttle the valve(s) of the other
(cooler) row(s) step-by-step, each time waiting for a few minutes, and check the temperature. Once all rows feel
uniformly cool, the system is balanced and operates at optimum performance. Should unexpected problems be
encountered, the flow rate must be checked out more thoroughly.

12 9
System Piping
Optional Isolation Valves
Isolation valves may be installed in the collector piping, so that the pool
may be operated while the collectors are being serviced, or during
freezing weather. Install a manually operated ball valve in the system
feed line, and a check valve on the return line.

• Both valves, available in the Supplemental System Isolation Kit (PN 12033-5) are made to accept either 1½” or 2”
PVC pipe. Make sure that the arrow on the check valve is pointing away from the collectors, and that the ball valve
and check valve are located close to the control valve and outlet ‘T’, respectively.

For further precautions in warm climates where pools are operated year round and periodic freezes can occur, a bypass
line (small diameter tubing), can be located above the ball and check valve so as to prevent any accidental trapping of
water in the collectors by the pool owner. To make sure no water is left in the collectors for servicing or during freezing
conditions, remember that the pool pump should be shut off, allowing the collectors to drain naturally, before the
optional isolation valves are used.

If the system is installed on a commercial or public pool, local codes may

require positive isolation valves in the collector feed and return lines, and
a pressure-relief valve in the piping to the collectors.

Control Systems
Control Types
Automatic Control: The performance of a solar pool heater can be maximized with the use if an electronic control and
motorized 3-way valve. When solar energy is available, the control activates the motorized valve, sending water
through the collectors for heating (or nocturnal cooling). When the pool reaches the set temperature, or there is
insufficient solar energy available, the valve will turn to bypass the solar system. Refer to the manufacturer’s
instructions included with the automatic control you use.

Manual Control: Some systems employ a manual control valve to divert the flow of water to the solar system, though
this may reduce the overall heating capacity of the system. Pool water continuously flows through the solar system
when the filtration pump is on, but can be diverted manually if the pool becomes too warm or during extended periods
of insufficient solar energy. A manual control system consists of a non-positively sealed 3-way valve in place of the
motorized valve.

Booster Pump System: In some cases, the existing pool filtration pump may not be able to circulate water at a high
enough flow rate to allow for proper collector operation. If so, it may be necessary to replace the filter pump with a
larger one, or add a booster pump. An increase in pump size may require an upgraded filter with greater flow ratings.

Regardless of control type, the three-way diverter valve used should be

non-positively sealed in order for proper system drain back to occur.

13 10
Checking for Operations
System Startup, Testing, and Troubleshooting
Each time the solar system cycles on, there are a few things to watch for:

✓ Air will initially be purged into the pool. This may last several minutes.
✓ The filter pressure will increase slightly and remain elevated when pool water is flowing through the solar system.
✓ When the system is running, all the collectors should feel uniformly cool to the touch.

Vacuum Relief Valve Test: When the solar system is first turned on, air in the collectors will be expelled into the
pool and bubbles will appear. The appearance of bubbles in the pool should stop after a few minutes.

• If, after a few minutes, bubbles continue to be discharged from pool returns, remove the Vacuum Relief Valve(s)
and replace it with an End Cap. If the bubbles discontinue, the issue may be the Vacuum Relief Valve location.

• If bubbles continue, reverse the End Cap and the Vacuum Relief Valve on the collector array to see if this stops the
bubbles in the return lines.

• If bubbles continue after reversing the VRV and End Cap, relocate the VRV to a position in the inlet piping at a
height of approximately 3/4 of the elevation of the collectors above the pool. Refer to Figure 2.

Flow Rate Test Methods:

1. Flowmeter: The preferred system test method is flow rate. This is also the easiest and quickest method. To
check flow rate, install a flow meter in the inlet line to the collectors (follow installation instructions provided
with the flowmeter).

2. Touch Method: With the system running and the sun shining, all collectors of the system should be uniformly
cool to the touch, and the system will be operating at optimum performance.

3. Temperature Rise Method: An alternate method to test adequate flow is by measuring the temperature rise
of pool water through the system. It is important that the temperature rise through the collectors be kept
as low as possible in order to deliver the maximum amount of heat to the pool. Use two accurate
thermometers - one in the pool water or filtration piping prior to the collectors, and one in the system outlet
piping - to measure the temperature rise from solar.

• Before installing, immerse both thermometers in the pool water for several minutes to compare temperature
readings. If they are not identical, make a notation of the difference and add or subtract (as appropriate) this
difference to or from the reading taken while you are testing.

• Turn the pump on and move the flow switch to the “Manual ON” position to divert pool water through the
collectors. After at least fifteen minutes of flow to collectors, compare the temperature of the pool water with
the water flowing through the outlet piping.

On an average sunny day, with the air temperature approximately 70°F (40°C) the water leaving the
collectors should be 1° to 7°F (1° to 4°C) higher than that in the pool. If the water rise is greater thanks
this, insufficient water is flowing through the collectors. This may be caused by a clogged filter,
undersized piping, too many elbows in the piping or an inadequate pump.

14 11
Maintenance
Pool Service & Maintenance
Backwashing & Adding DE: It is advisable to bypass the solar collectors when either backwashing your filter or
adding Diatomaceous Earth (DE). This prevents the possibility of any DE or other debris from passing through the solar
system as well as any other pool equipment downstream of the filter. When the backwashing cycle and/or the adding of
DE is complete, run the filtration system for 10-15 minutes before returning your solar heating system to operation.

Automatic Pool Cleaning Systems: If you have an automatic pool cleaning system with its own pump, there may
be several precautions that you need to take depending on what type of system you have. These precautions prevent
the air that is initially purged from the solar system from possibly damaging pool cleaning equipment during the turning
on cycle of your solar system.

• Manual Control: Do not start the flow of water through the solar collectors while the pool cleaning pump is running.
Allow the air to be purged from the system and then activate your pool cleaning system.

• Automatic Systems: If your automatic control system is not equipped with a timed pool cleaner delay cycle, it will
be necessary to run your pool cleaner in the early morning and turn it off before your solar system comes on; or turn
it on in the late morning, well after your solar system normally cycles on. If you manually vacuum your pool,
bypassing the solar collectors at this time will provide you with full power for better vacuuming performance.

Cold Weather Operation & Winterization Procedures

During normal operation of the system, when the 3-way valve is in the “bypass collector” position, all water in the
collectors should drain back through the 3-way valve (non-positively sealed) when the filter pump shuts off. If there is an
isolation ball valve on the feed line, it should only be closed after the collectors have drained fully. Provided collectors
are drained, there are no further requirements for winterizing the solar collectors. The pool piping should be winterized
as per your normal practice.

In some areas, pool owners operate their pools throughout the winter although light freezing conditions may occur.
When solar heaters are used on a pool under these conditions, anti-freeze precautions should be taken. In order to
protect the collectors as well as appurtenant components such as End Caps and pipe fittings against unusual or severe
freezing conditions, one of the following two procedures should be followed when freezing weather is imminent.

1. If isolation valve(s) have been installed, turn circulating system off and allow solar collectors and piping to drain.
Close isolation valve(s) if applicable. Switch the solar control to “OFF” or “Solar Disabled”. The pool filtering system
may then be turned back on. When freezing conditions have passed, open isolation valve(s) and switch the solar
control to “AUTO” or “Solar Enabled”.

2. If the system can not be drained and isolated, the accepted procedure for avoiding freezing of the pool piping and
filtration system has been to continuously circulate the water. Switch the solar control to the “Manual ON” position
so that water circulates through the collectors. When freezing conditions have passed, switch the solar control to
“AUTO” or “Solar Enabled”. This method is not recommended where temperatures may drop severely.

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Booster Pump System Diagram
In some cases, the pool filtration pump may not be able to circulate water at a high enough flow rate to allow for
proper collector operation. If so, it may be necessary to replace the filter pump with a larger one or add a booster
pump. If the pump size is increased, it may also be necessary to upgrade the filter to one with greater flow ratings.

For the latest revision of this manual, or to view the complete unabridged
manual, please visit www.aquathermindustries.com/install

An ISO 9001:2008 Registered Manufacturer

Aquatherm Industries, Inc.

1940 Rutgers University Blvd.
Lakewood, New Jersey 08701

Phone: 732-905-9002
Email: [email protected] INDUSTRIES,INC. ®
Part No. 19001 Rev. 4/15 © 2015 Aquatherm Industries, Inc.
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