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SWIMMING POOL
SOLAR HEATING SYSTEMS
INSTALLATION MANUAL FOR
AQUATHERM INDUSTRIES
SOLAR COLLECTORS

FOR MODEL NUMBERS:

10001-5 10204-12 16104-12 16204-12 16404-12

10001-2 10204-10 16104-10 16204-10 16404-10
10001-1 10204-08 16104-08 16204-08 16404-08

MANUAL CONTENTS CAUTION: SOLAR COLLECTORS ARE OFTEN INSTALLED

ON THE ROOFS OF BUILDINGS. UNLESS YOU ARE VERY
This manual provides a detailed step-by-step pro- FAMILIAR WITH WORKING ON ROOFS AND HAVE THE
cedure for the installation of an Aquatherm PROPER LADDERS AND SAFETY EQUIPMENT FOR
Industries solar pool heating system. If the direc- SUCH WORK, YOU SHOULD HIRE SOMEONE WITH THE
tions are followed correctly and only recommended NECESSARY EXPERIENCE TO DO THE INSTALLATION.
Aquatherm Industries hardware and components FAILURE TO OBSERVE SAFE PRACTICES ON A ROOF OR
are used, the installed system should provide years OTHER ELEVATED STRUCTURE MAY RESULT IN FALLING,
of trouble free service, savings, and enjoyment. LEADING TO SERIOUS INJURY TO YOU.
MOUNTING
COMPONENTS
DIAGRAM

MOUNTING COMPONENTS
This section provides descriptions and part numbers of the
Aquatherm Industries Installation Kits required for each
solar pool heating system. The mounting location of each
kit component is shown by the corresponding circled num-
ber in the ‘Mounting Components’ diagram, shown above.

2 The System Kit (Part #12135-1 for 1 1/2” kit; #12135-2

for 2” kit) contains additional hold-down hardware, connec-
tion parts and adapters needed to complete water connec-
tions from the collectors to the system feed and return line.
The pipe adapters that connect the system piping to the col-
lectors are high temperature CPVC. The system check
valve is 1 1/2” - 2” PVC. Installation and homeowner man-
uals are also included. Use one (1) kit per system.
Part No Qty 1 1/2” Qty 2” Description
10003-1 1 __ Vacuum Relief Valve
10003-2 __ 1 Vacuum Relief Valve
10008-1 1 __ Outlet header hold-down bracket assembly
1 The Collector Installation Kit (Part #12034-1 for 1 1/2” kit; 10008-2 __ 1 Outlet header hold-down bracket assembly
#12034-2 for 2” kit) contains the parts needed to fasten a single 10011 4 4 Hold-down strap clamp assembly
solar collector to a supporting surface and to make water connec- 30061-1 1 __ End cap
tions from one collector to another. Hold-down strap is not includ- 30061-2 __ 1 End cap
ed and must be ordered separately Use one (1) kit per collector. 30089-1 2 __ Pipe adapter
30089-2 __ 2 Pipe adapter
Part No Qty 1 1/2” Qty 2” Description
__ 50006 2 2 Hold-down strap bracket
10008-1 1 Outlet header hold-down bracket assembly 60649-1 2 __ System connector hose (7” long)
10008-2 __ 1 Outlet header hold-down bracket assembly 60649-2 __ 2 System connector hose (7” long)
50006 2 2 Hold-down strap bracket 60546-1 4 __ Hose clamp, stainless steel
60648-1 2 __ Collector connector hose (3 3/4” long) __
60546-2 4 Hose clamp, stainless steel
60648-2 __ 2 Collector connector hose (3 3/4” long) 60019-2 1 1 Check Valve (1 1/2” & 2”)
60546-1 4 __ Hose clamp, stainless steel 19001 1 1 Installation Manual
60546-2 __ 4 Hose clamp, stainless steel ----- 1 1 Owner’s Manual

2
2A The Optional Supplemental System Isolation Kit 5 The Row Spacer Kit (Part #12017-1 for 1 1/2” kit; #12017-2
(Part #12033-5) includes a 1 1/2” - 2” PVC union ball for 2” kit) is used when a row of collectors must be interrupted by
valve and a 1 1/2” -2” PVC check valve to permit manu- a space to allow for obstructions such as a chimney or roof vent.
al isolation of the solar system from the pool or spa fil- It contains the hardware needed to space around any width
tration system. Use one (1) kit per system. obstructions by connecting appropriate lengths of PVC pipe to
the pipe adapters at the inlet and outlet headers of the two col-
lectors on either side of the obstructions. Use when required.
3 Hold-Down Strap is required to secure collectors to Part No Qty 1 1/2” Qty 2”
__
Description

the mounting surface. Use strap 10035-1 (54’) for rows of 10008-1 1 Outlet header hold-down bracket assembly
10008-2 __ 1 Outlet header hold-down bracket assembly
up to 6 collectors or strap 10035-2 (107’) for rows of up to
10011 4 4 Hold-down strap clamp assembly
12 collectors. Available in bulk, 1400 ft. roll. Part #10040. 30089-1 4 __ Pipe adapter
30089-2 __ 4 Pipe adapter
50006 2 2 Hold-down strap bracket
60648-1 2 __ Collector connector hose (3 3/4” long)
60648-2 __ 2 Collector connector hose (3 3/4” long)
60546-1 4 __ Hose clamp, stainless steel
60546-2 __ 4 Hose clamp, stainless steel

6 Double Hole Outlet Header Bracket (Part #50069) may

also be used to terminate a strap run in high wind areas where
extra hold-down strength is required.

4 The Add-A-Row Kit (Part #12043-1 for 1 1/2” kit; #12043-

2 for 2” kit) is used when more than one row of collectors is to
be installed. Use one (1) kit for each collector row after the first.
Part No Qty 1 1/2” Qty 2” Description
10003-1 1 __ Vacuum Relief Valve 7 Aluminum Mounting Bracket & Header Clamp Assembly
10003-2 __ 1 Vacuum Relief Valve
10008-1 1 __ Outlet header hold-down bracket assembly
10008-2 __ 1 Outlet header hold-down bracket assembly
10011 4 4 Hold-down strap clamp assembly
30061-1 1 __ End cap
30061-2 __ 1 End cap
30089-1 2 __ Pipe adapter
30089-2 __ 2 Pipe adapter
50006 2 2 Hold-down strap bracket The Aluminum Header Clamp Assembly (Part #30171-1 for
60649-1 2 __ System connector hose (7” long) 1 1/2” only) is used as supplemental outlet header mounting in
60649-2 __ 2 System connector hose (7” long) conjunction with the Outlet Header Hold-Down Bracket assembly
60546-1 4 __ Hose clamp, stainless steel (Part #10008-1). The bracket is designed for installations that
60546-2 __ 4 Hose clamp, stainless steel require more flexibility for the outlet header mounting hardware
location, such as barrel tile roofs or installations that require addi-
tional mounting hardware to be anchored into rafters or beams.

The Aluminum Header Clamp Assembly (Part #10117-1 for

1 1/2”; #10117-2 for 2”) is used the same as the Aluminum
Header Bracket (Part #30171-1) and allows for collector
replacement without disturbing the roof penetrations.

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 8 Header Inserts (Part #50055-1 for
1 1/2”; #50055-2 for 2”) are used
MOUNTING THE SOLAR COLLECTORS
in special situations where Refer to Figure 1 throughout this section. When mounting
unusually high stagnation the collectors, always make provisions for inlet connec-
temperatures are expected, tions at the bottom header and outlet connections at the
such as in a desert climate top. The outlet headers must be pitched a vertical dis-
or where abnormally high tance of at least 8” (20cm) above the inlet headers to
system pressures may occur. assure proper drainage and uniform flow. Plan the col-
Use four (4) inserts per collector. lector location to allow at least one foot on all sides of the
row of collectors for mounting brackets and piping. The
outlet pipe for each row of collectors must be connected
9 The Optional Supplemental High Wind Area diagonally opposite the inlet pipe. Refer to Figure 2.
Collector Hold-Down Kit (Part #12035-1 for 1 1/2”,
#12035-2 for 2”) used in addition to the basic collector
installation kit in regions where high winds are prevalent.
Requires twice the amount of hold-down strap.

Figure 2

DISTANCE BETWEEN PANEL

HEADERS AND STRAPS
Collector Collector Collector
Panel Size (A) Distance (B) Distance
in feet
_________ inches (cm) inches
_________ (cm)
_________ Figure 1
12 60 (152)
10 48 (122) ASSEMBLY ON
8 36 (91) 16 (40) ROOF DIAGRAM
6 24 (60)
4 _____

4
1) Determine the position of the last outlet header hold-
down bracket for the row of collectors. Mark this point on
Figure 5
the roof. The collector outlet headers will be located approx-
imately 1” (25mm) below this mark. Refer to Figure 3.

Figure 3

outlet header bracket chalk line, snap another chalk line

parallel to this line using the “A” dimension. The “B”
dimension is the same for all collector sizes, which is 16”
(40cm) up from the outside of the bottom header and can
be measured after the collectors are installed. Wait to
2) Using this point, snap a chalkline to the opposite end install the hold-down strap brackets until after the collec-
of the row. Slope this line down the roof toward the inlet tors are installed so as not to damage the collectors
approximately 1” (25mm) for each 6 collectors in the row. when you are bringing them to the roof for installation.
Using a 1/8” (3mm) drill bit (for 1/4” (6mm) diameter
screws) drill a hole for the first outlet header bracket on 5) Bring the first collector to the roof and slip the proper
the first roof mark. Measure up 1” on center from the first hoses over both ends of the inlet and outlet headers on
pilot hole and drill pilot hole for second screw. Repeat this the last return collector. Make sure that the side of the
process all along the chalkline for the total number of col- collector with the serial number label on it is facing down.
lectors to be installed. The long hoses go on the outlet of the last collector and
the inlet of the first collector. Push UP TO the hose locat-
Figure 4 ing shoulder, but NOT OVER it. Locate a hose clamp
3/8” (10mm) from the end of the hose in order to center
it on the header groove. This clamp must face up so as
to be accessible for tightening and will not rub against the
mounting surface. Make sure you securely tighten each
clamp with a nutdriver. If a nutdriver is not available, a
‘hex’ wrench or screwdriver will suffice. THE HOSE
CLAMPS MUST BE LOCATED OVER THE GROOVES
IN THE HEADER.

6) Position the collector on the roof so that the center of

the outlet connection hoses are directly beneath the
secured outlet header brackets and slip the bracket hold-
down clamps over the connection hoses. Lightly tighten
the clamp around the header hose. Refer to Figure 5.
3) Inject a generous amount of high quality sealant into Continue to install all the collectors in the array, coupling
each hole and onto the surrounding roof surface. Bolt all them side to side.
the outlet header hold down brackets to the roof as
shown in Figure 4. 7) If the Aluminum Header Clamp Assembly is to be used
for supplemental mounting hardware, install them after
4) Locate the hold-down strap bracket holes using the both the outlet header brackets and the collectors have
information in Fig. 1, Table A. Measuring from the top been installed.

5
7) Proceed to the lower chalk line previously snapped on
the roof for the hold-down strap brackets. Mark a hole 2”
Figure 8
(5cm) to the side of the first collector and continue mark-
ing holes on the chalkline centered exactly between the
absorber surfaces until you reach the last collector.
Mark the last hole the same 2” (5cm) to the side of the
last collector. Drill a pilot hole and apply sealant at each
of these locations. Bolt the hold-down strap brackets on
the roof. Refer to Figure 6. It is OK to step on the col-
lectors as long as you stay one foot away from the top
and bottom headers. Mark the holes for the bottom hold- both slots in the bracket located on the other side of the
down strap by measuring up 16” (40cm)from the outside collectors. Pull the straps taut against the face of the
of the bottom header and again centering them between collector. Repeat this procedure for the remaining hold-
the absorbers and 2” (5cm) away from the first and last down strap. Refer to Figure 9.
collector.
Figure 9
Figure 6

8) Install the vacuum relief valve in the outlet header of

each row. This will be located at the opposite end of the
row that is connected to the collector outlet pipe. Refer
to figure 2, 11, and 12.

9) Install an end cap in the inlet header of each row,

opposite the end that is connected to the collector inlet
pipe. Refer to Figures 2, 11, and 12.

10) INSPECT THE INSTALLATION AND CHECK ALL

CLAMPS FOR PROPER POSITION AND TIGHTNESS.

Installation Over Roof Vent Pipes

Slip one end of a hold-down strap through the slot in the
Collector models with intermittent sonically welded plates
hold-down strap bracket at the end of the row, then through
can be installed over or around different diameter roof vent
the strap clamp and out through the other slot in the hold-
pipes or other obstructions up to 2” (63mm) in diameter.
down bracket. Pull about 3” (7-8cm) of the strap through
After snapping the top chalk lines but before marking and
pre-drilling for your outlet header brackets, locate the seam
Figure 7 in the collector nearest to where the vent pipe is to come
through. Separate by pulling up on top plate, 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 weld while pulling the two
plates apart. Lay the collector over the vent pipe, keeping
the vent pipe at least 12” (30.5cm) away from a header. It
will be easier to complete an installation by mounting this
collector first and then working away from it.
and bend it back toward the clamp. Refer to Figure 7.
Slip the loose end of the strap through the strap clamp
and pull it tight. Clamp screw (A) should be tightened
securely, but not over-tightened to the point where the
clamp is distorted. Refer to Figure 8. Bring the remain-
ing strap end across the collector face, passing through

6
With a roof vent pipe of 3” (8cm) in diameter, the collec- Whenever there is more than 40 gpm (151.6l ) required
tors can be positioned on either side of the vent. Two sys- flow rate to the collectors or more than 100’ (12m) of pip-
tem connector hoses (Part #60649-1/-2) can be employed ing used in a system, install 2” (63mm) piping to and from
to couple the collectors together for vent pipes or other the collectors.
obstacles up to 7” (17cm) in diameter. Mark your 51”
(1.3m) centers wherever the outlet header brackets ‘fall’ Piping to and from the collectors should be the same type of
on the upper chalk line. With obstructions of over 7” plastic piping and fittings approved for use with swimming
(17cm), such as attic fans and skylights, lay out the col- pool filters and pumps. It is recommended to always use
lectors on either side of the obstruction using a Row Schedule 40 PVC pipe and fittings. Although PVC pipe is
Spacer Kit (Part #12017-1 for 1 1/2”; #12017-2 for 2”). generally white, black is also available but may be difficult to
find locally. If for aesthetics black pipe is desired it can
System Piping always be painted black. Use a PVC cutter or a PVC wide-
Refer to Figures 10 & 11, throughout this section. The blade saw (not a hacksaw) for cutting pipe. It is important to
most common piping configurations use a pressure filter. use both a quality cleaner/primer and solvent in gluing a PVC
The pump draws the water from the skimmer and/or a joint. For more detailed information on PVC gluing refer to
main drain, forcing it through the filter and sending it back Engineering Bulletin No. 8701. Finally, use a cloth while
to the pool through the return lines. either gluing or painting to keep the job a clean one. Piping
should also be supported at intervals of 5’ (1.5m) for hori-
If a fuel-fired heater is installed, it is located between the fil- zontal pipe and 8’ (2.5m) for vertical pipe. Use either galva-
ter and the return line to the pool. The pipes to and from the nized or plastic pipe clamps. Aquatherm Industries outlet
solar collectors are connected to the return line to the pool header bracket assemblies (Part #10008-1/-2), which are
before the water enters the fuel-fired heater, if one is used. made of stainless steel, are also excellent pipe hangers.

Figure 10
PLUMBING
SYSTEM
SCHEMATIC

7
Manual Systems Table B COLLECTOR SIZE
4x12 4x10 4x8
Recommended flow rate per collector, gpm/l 5.0/18.9 4.0/15.1 3.25/12.5
Some systems can employ a manual control valve to con-
trol the flow of water thru the solar collectors, although this Minimum flow rate per collector, gpm/l 3.0/11.4 2.5/9.5 2.0/7.6
may reduce the overall heating capacity of the system. Maximum # collectors per row 10 12 14
The manual control valve usually consists of a non-posi-
tively sealed 3-way valve as shown in Diagram 10. Water
continuously flows through the solar collectors when the
filter pump is on, but can be diverted manually by the pool uniformly cool to the touch, and there should be no resid-
owner if the pool becomes too warm or during extended ual air left in the pool return lines. If either of these two
cloudy weather. During a threat of freezing conditions it conditions persist, chances are that the flow rates thru
can also be diverted, by first shutting off the pool pump, the collectors are inadequate or the system is not prop-
allowing the collectors to drain, diverting the 3-way manu- erly balanced. A flow meter can be installed in the col-
al valve to the “bypass collector” position and shutting the lector feed line to check on the flow rate. If the flow rates
isolation valves on the collector feed and return lines. A are within the limits as shown in Table B, then the sys-
lower end cap on the collectors or any of the connecting tem may not be properly balanced, especially with sys-
hoses can be removed to make sure there is no standing tems requiring multiple banks of collectors. Refer to the
water in the collectors. The filter pump can then be re- following section on Special System Layouts.
started to allow for normal pool filtration.
If the flow rate is below the minimum as shown in the
During normal operation of the system when the 3-way table above, then the pool pump horse power or pipe
valve is in the ‘bypass collector’ position all the water in the size should be increased, or a booster pump installed in
collectors should drain back through the 3-way valve (non- some cases. If the long hoses on the inlet and outlet pip-
positively sealed) when the filter pump shuts off. An alter- ing connections “suck in”, then slip a piece of 1 1/2”
nate way to protect against sudden freezes can be accom- (50mm) pipe into the hose to prevent this. And also, if
plished by running a bypass line (1/8”-1/4”, 3-6mm) the flow rate is excessive (more than 10 GPM/(37.9l )
between the collector feed and return line above the isola- collector), or if the system pressure is greater than 30
tion valves, if any. It is possible that a small amount of water psi, a bypass line should be installed between the col-
may be present in the collectors when a non-positively lector feed and return lines above the 3-way valve to pre-
sealed 3-way valve is used and the filter pump is on. If a vent problems with the collectors and connection hoses.
positively sealed 3-way valve is used, a bypass line as men-
tioned above is mandatory to allow for collector drainage. If there is residual air in the pool return lines and the col-
lectors do feel cool to the touch, refer to the section con-
cerning the vacuum relief valve test on page 10.
AUTOMATIC CONTROL SYSTEMS
The performance of a solar pool heating system can be
improved with the use of an electronic control and motor- Optional Isolation Valves
ized 3-way valve. The control activates the motorized Isolation valves may be installed in the collector piping
valve and either sends water thru the collectors for heating so that the pool may be operated while the collectors are
(or nocturnal cooling) or automatically bypasses the collec- being serviced or during freezing weather. Install a man-
tors when the pool is warm enough or insufficient sunlight ually operated ball valve in the collector inlet line and a
is available. Refer to the manufacturer’s instructions check valve on the collector return line. Both valves,
included with the automatic control you use. available in the Optional Supplemental System
Isolation Kit (Part #12033-1) are made to accept either
Other Equipment 1 1/2” or 2” PVC pipe. Make sure that the arrow on the
check valve is pointing away from the collectors, and that
Some pools employ an automatic pool cleaner. This
the ball valve and check valve are located close to the
should be plumbed before the control valve to assure
control valve and outlet ‘T’, respectively. For further pre-
positive flow to the cleaner at all times. If the pool uses
cautions in warm climates where pools are operated
an automatic chlorinator, this should be plumbed after
year round and periodic freezes can occur, a bypass line
the outlet tee on the return to the pool.
(small diameter tubing) can be located above the ball
and check valve so as to prevent any accidental trapping
Flow Rates of water in the collectors by the pool owner. To make
In order to receive optimum results from Aquatherm sure no water is left in the collectors for servicing or dur-
Industries collectors, the following recommended flow ing freezes, remember that the pool pump should be
rates and number of collectors per row should be followed. shut off, allowing the collectors to drain naturally, before
When the system is running, all the collectors should feel the optional isolation valves are used.

8
Special System Layouts loop, pump size, and electrical energy requirements may
Use a divided system when installing more than the rec- be reduced.
ommended maximum number of collectors per row,
when avoiding roof obstructions, or where limited space SYSTEM START-UP AND TEST
dictates. This provides uniform distribution of water
through all the collectors. If water distribution through the
System Start-up and Checkout for
collectors is non-uniform, the heating capacity of the sys- Automatic Systems
tem will be reduced. To check out the system for proper operation turn on the
filter system. Set the temperature control to its highest
WHEN INSTALLING A DIVIDED SYSTEM, THE OUT-
level. Switch the control to the “flow through collector”
LET HEADERS FROM EACH OF THE LOWER (OR
mode. The “flow through collector” light should come on.
CLOSEST) ROWS OF COLLECTORS MUST BE CON-
The 3 way valve will then be sending water thru the col-
NECTED TO THE HIGHEST (OR FURTHEST) POINT IN
lectors, and air will be purged out of the collectors into the
THE SYSTEM. Refer to Figure 11.
pool return line for several minutes, and should then clear.
A divided system requires an Add-A-Row Kit (Part The collectors should feel uniformly cool to the touch.
#12043-1/-2) for each row of collectors. Switch the control to the “bypass collector” mode. The cor-
A more complex divided system is shown in Figure 12. responding light will go on and the 3 way valve will be
This also illustrates the application of the Row Spacer Kit sending water directly back to the pool, bypassing the
to clear a roof obstruction. solar collectors. After about 5-10 minutes, feel the solar
collectors again. They should have begun to warm up.
Booster Pump System Now switch back to the automatic mode. If the sun is still
In some cases, the pool filter pump may not be able to cir- shining on the solar collectors, the “flow thru collector”
culate water at a high enough flow rate to allow for proper light should go on again. Adjust the temperature control
collector operation. If so, it may be necessary to replace lower.
the filter pump with a larger one or add a booster pump. If
When you reach the actual temperature of the pool
the pump size is increased, it may also be necessary to
water, the light will turn off. The flow bypass collector
upgrade the filter with one with greater flow ratings.
light will go on again. Move the temperature control to
Supplemental Gas, Oil-Fired, maximum and leave there. The “flow through collector”
light will go back on. For more detailed information on
or Electric Heaters the system startup, trouble shooting and valve/control
It is desirable to pipe the stand-by heater in a bypass installation, follow the manufacturers’ instructions includ-
loop. Refer to Figure 10. Fuel-fired heaters often create ed with the automatic control system.
a large pressure drop. By placing a heater in a by-pass

Figure 11
DIVIDED
SYSTEM
ASSEMBLY
ON ROOF

9
 Figure 12

Manual Control of System make a notation of the difference and add or subtract (as
To test collector operation, follow either the flow-rate or appropriate) this difference to or from the reading taken
temperature-rise procedure. Divert water through the col- while you are testing. This is necessary in order to pro-
lectors. Turn on the pump and either observe flow rate or vide an accurate indication of the temperature rise of the
temperature rise. The flow rate or temperature rise would water passing through the solar collectors.
be the same as that specified in the “System Start-Up and
Turn the pump on and move the flow switch to the “COLL”
Test” section. If it is not, then check for the indicated prob-
position. Observe valve action...it should divert water
able causes and make necessary corrections.
through the collectors. After flow through the collectors has
continued for a least fifteen minutes, compare the pool
Flow Rate Test Method water temperature with the temperature of the water flow-
The preferred system test method is flow rate. This is also ing through the outlet line. On an average sunny day, with
the easiest and quickest method. To check flow rate, install the air temperature approximately 700F (210C) the water
a flow meter in the inlet line to the collectors (follow instal- leaving the collectors should be 1 to 70F (1 to 40C) higher
lation instructions provided with the flowmeter). than that in the pool. If the water rise is greater than this,
insufficient water is flowing through the collectors. This
Temperature Rise Test Method may be caused by a clogged filter, undersized piping, to
An alternate test method is temperature rise. To prepare many elbows in the piping or an inadequate pump. It is
the system for testing, obtain two accurate thermometers. important that the temperature rise through the collec-
Aquatherm Industries dial thermometers (Part #60054-2) tors be kept as low as possible in order to deliver the
are excellent for this application. One of these ther- maximum amount of heat to the pool.
mometers is installed in the outlet line from the collectors
as shown in Figure 10. The other is used to check the Vacuum Relief Valve Test
temperature of the pool water, to compare it with that of When the solar system is first turned on, air in the collec-
the water leaving the solar collectors. Before installing tors will be expelled into the pool and bubbles will appear.
the thermometer in the outlet line, immerse both ther- The appearance of bubbles in the pool should stop after
mometers in the pool water for several minutes to com- a few minutes. If, after a few minutes, bubbles continue
pare the temperature readings. If they are not identical, to be discharged at the return to the pool,remove the vacuum

10
relief valve(s) and replace it with and end cap. Relocate Annual Service
a vacuum relief valve to a position in the inlet piping Collector Clamps:
which is at a height of approximately three-fourths of the
elevation of the collectors above the pool. Refer to In particularly hot climates, such as Arizona and
Figure 1. Southern Florida, the clamps which are used to connect
(A quicker alternate method is to first try to reverse the the solar collectors may become loose. If you notice
leaks around the hose couplings, use a nutdriver to tight-
end cap and the vacuum relief valve on the collector
en clamps. Do not tighten to the extent that the pipe col-
array to see if this stops the bubbles in the return lines. lapses or the clamp gears strip. In areas where unusu-
Sometimes the end cap is about 3/4 of the elevation of ally high stagnation temperatures are prevalent or where
the collectors and this is a lot quicker than cutting in a tee abnormally high system pressures occur, use header
in the supply pipe.) insert (Part #50055-1/-2).

MAINTENANCE COLLECTOR REPAIR

Winterizing Procedures This method allows for an easy and permanent on site
The solar collectors should drain automatically each time repair of a collector by isolating the leaking riser tube.
the pump cycles off. There are no special requirements Referring to the figure below, locate the tube to be isolat-
for winterizing the solar collectors. The pool piping ed. (End tube has been shown for clarity.) Using a sharp
should be winterized as per your normal practice. In utility knife, very carefully cut away approximately 1” of
southern parts of the country pool owners operate their the tube at both headers. Drive a #10 - #12 sheet metal
pools throughout the winter although light freezing condi- screw, preferably stainless, into the hole in the header.
tions may occur. The accepted procedure for avoiding The screw must be between 1/2” and 3/4” long. DO NOT
freezing of the pool piping and filtration system has been OVERTIGHTEN! If the screw strips out, or if the repair
to continuously circulate the water. When solar heaters leaks, use a larger screw. This repair method will not
are used on a pool under these conditions, anti-freeze void the collector warranty.
precautions should be taken. Aquatherm Industries solar
collectors are not normally affected by light freezing.
However, in order to protect appurtenant components
such as end caps and pipe fittings and the collectors
against unusual or severe freezing conditions, one of the
following two procedures should be followed when freez-
ing weather is imminent.
1. Turn circulating system off and allow solar collectors
and piping to drain. Isolate collectors with gate or ball
valve in collector feed line and a check valve in the col-
lector return line. Switch the solar control to the bypass
position. The pool filtering system may then be turned
back on. When freezing conditions have passed, open
isolation valves and switch the solar control to “AUTO”.
2. Switch the solar control to the “COLL” position so that
water circulates through the collector. When freezing con-
ditions have passed, switch the solar control to “AUTO”.
THIS METHOD IS NOT RECOMMENDED WHERE
TEMPERATURE LEVELS MAY DROP SEVERELY.

11
 Figure 14
BOOSTER PUMP
SYSTEM DIAGRAM
FOR OUTDOOR POOLS

1940 Rutgers University Blvd.

Lakewood, New Jersey 08701
1-732-905-9002
Part No. 19001 Rev. 12/05 ©2005 Aquatherm Industries Solar Pool Heating Systems
12