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Pool Warehouse SUNRAY Installation Manual
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Pool Warehouse SUNRAY Installation Manual

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V35068
INSTALLATION MANUAL - CHANNEL LOK II OVAL POOLS
S UN RAY
POOL MODEL -
02.13

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Summary of Contents for Pool Warehouse SUNRAY

  • Page 1 V35068 INSTALLATION MANUAL - CHANNEL LOK II OVAL POOLS S UN RAY POOL MODEL - 02.13...
  • Page 3 Above Ground Pool SAfety PleASe reAd before inStAllAtion Failure to heed these warnings can result in permanent injury, paralysis From a broken neck, electrocution or drowning. warning this pool is not designed For diving or jumping! dangerous injury can result, shallow water! your pool contains a large quantity of water, and is deep enough to present inherent dangers to life and health unless the follow- ing safety rules are strictly observed.
  • Page 5 General Instructions - Channel Lok II Oval Pools ection Ground Preparation Read all instructions completely before you begin. A. Determine a Location for your Pool 1. The Terrain • Pay special attention to choosing the right location for your pool: • Choose a large area, as flat and level as possible and well drained. • Choose a spot on dry, firm earth— do not install the pool on concrete, asphalt, tar paper, sand, gravel, peat moss, wood or chemically treated soil. • Check with your pool dealer to see Important Note: if Nut Grass grows in your area.
  • Page 6 Things to Avoid Do not locate your pool near or on any of the following: • Overhanging tree branches. • Overhead wires and clotheslines. • Buried pipes and wires-contact your gas, electric and telephone utilities to find buried pipes and wires before you dig. • Hilly and uneven terrain. • Areas with poor drainage. • Grass, stones and roots. Grass will rot underneath the pool liner, and stones and roots will damage the pool liner. • Areas recently treated with oil-based Important: weed killers, chemicals or fertilizers. When locating the centre of the pool, be sure to take into consid- eration any structures Plan Ahead (deck, patio, house) or • Will you be adding an adjacent deck relevant items (change later? Be sure to leave room. rooms, gazebo, etc.) that the pool may need • Will you be using pool accessories or to line up with and other appliances that need electricity or ensure that the pool is in gas? Locate your pool near these services the most visual pleas- or plan to have them installed later by a ing location for your property. licensed contractor. Tools Needed Make sure you have the necessary tools and materials before beginning your...
  • Page 7 PARTS LISTING - EXPLODED VIEW Sunray STR PR2299XXXX Important Note: Round Make sure you have all the parts necessary before you start installation. No Diving or Jumping. Observe all Safety Rules.
  • Page 8 PARTS LISTING - EXPLODED VIEW Sunray STR PV2299XXXX Channel Lock OVAL SIDE No Diving or Jumping. Observe all Safety Rules.
  • Page 9 PARTS LISTING - CONTENT LIST Product Description: Sunray Oval Revised: Sept 2012 Product Code: PV2299XXXX Quantity required for installation (by pool size) INDEX # DESCRIPTION PARTS# LENGTH 1218 1224 1524 1530 1833 56 1/ 4" Top ledge TL10008 TL10013 63"...
  • Page 10 C. Prepare the Foundation of your Pool 1. Choose the Correct Ground Preparation Drawing a. Choose the drawing that matches your pool size from the five plan drawings below. Important: This drawing will have all of the necessary dimensions for the ground preparation When locating the instructions that follow. NOTE: Please be sure to use your pool's footprint for centreline of the pool, to take into your pool size on the last pages of this Section 1. be sure consideration any 12 x 18 (3,66m x 5,49m)
  • Page 11 15 x 24 (4,57m x 7,32m) 15 x 24 (4,57m x 7,32m) Oval Pool Dimensions R 93" (236 cm) S 105" (267 cm) L 49" (125 cm) M 25" (64 cm) N 48" (122 cm) P 96" (244 cm) W 114" (290 cm) X 90"...
  • Page 12 18 x 33 (5,49m x 10,05m) 18 x 33 (5,49m x 10,05m) Oval Pool Dimensions R 110-1/2" (279 cm) S 122-1/2" (310 cm) L 87-7/8" (221 cm) M 25-1/2" (64 cm) N 59-1/2" (150 cm) P 169-3/4" (429 cm) W 132" (335 cm) X 108"...
  • Page 13 2. Mark out the Area a. Drive two pegs (A) and (B) into the ground. These pegs will both be on the centreline of your pool. Choose the right distance between them from the chart below. Note: Distance A to B is equal to dimension P on the pre- vious ground preparation drawings. Pool Size Distance between two pegs (A) and (B) 12' x 18' (3,66m x 5,49m) 72" (183cm) 12' x 24' (3,66m x 7,32m) 144"...
  • Page 14 d. Drive a flat-topped stake (C) exactly halfway between the two pegs (A) and (B) on the centreline. Stake (C) will mark the exact centre point of your pool. The stake must be at least 1" (25 mm) square and 6" (15 cm) long. Drive it down flush with the ground surface. e. Replace the two pegs (A) and (B) with two more flat-topped stakes. Drive them down flush with the ground surface. f. Join the two circles with straight lines to make an oval. Use pegs and a piece of string as a guide for the can of spray paint. Important: Measure carefully to make sure the centre g. Mark areas along both straight sides stake (C) is in the cor- of your oval. Use pegs and string as rect location, exactly a guide for the can of spray paint to between pegs halfway mark straight lines. Use the chart be- (A) and (B). You will use stake (C) later as a low to find the correct width W from reference point for other the centreline of the pool. The ends of measurements.
  • Page 15 3. Remove the Sod a. Remove all sod and plants from the area. b. Remove any sticks, stones and roots from the area. 4. Make the Area Flat and Level a. You will use a 2-by-4 to help level the pool foundation area. Choose the length of straight 2-by-4 you need for your pool from the chart below. Pool Size Length of plank 2-by-4 (5cm x 10cm) 12' x 18' (3,66m x 5,49m) 84" (213cm) 12' x 24' (3,66m x 7,32m) 84"...
  • Page 16 d. Put a carpenter’s level on the 2-by-4 and swing the board in a circle to find the high and low spots. e. Remove all the high spots with a shovel, hoe or rake. To make sure your pool is stable, compact the ground well before adding the sand. Be prepared to hire earth moving equipment if you need to level a large area. Remember, your pool must be level across the diameter of the pool f. Small dips and hollows may be filled in, but the soil must be hard-packed with a tamping tool. g. Remove the 2-by-4 from the stake and nail it to the next stake on the cen- treline. h. Repeat the last five steps until the whole oval area is level. Take your time and make sure the area is perfectly level. If necessary, adjust the height of Hint: Use a surveyor’s transit each stake and keep scraping away soil instead of a carpenter’s until the entire area is level. level, if one is available. i. Take material such as rock dust or fine mortar that can conform a solid, per- manent base and deposit this material around the rim of the basin. The mate- rial used should be spread around the Remember: perimeter of the pool to a width of 24” The outer 12" (30 cm) (60cm) and a thickness of 2” (5cm).
  • Page 17 5. Add Corner Stakes a. Prepare eight corner stakes (D), (E), (F) & (G), and (H), (I), (J) & (K) by marking the centre point of each stake the same way as in step 4(c). b. Drive the eight corner stakes into the ground. Drive them down flush with the ground surface. Locate each stake exactly by using the measurements for your pool in the chart below. Be sure to measure using the centre point of each stake. c. Tie strings between stakes (H) and (I) and between (J) and (K). Pool Size Distance X Distance Y Distance W Distance Z 12' x 18' (3,66m x 5,49m) 72" (183cm) 80-1/2" (204cm) 96"...
  • Page 18 c. Repeat steps (a) and (b) to locate the next trench along the side of the pool. Measure the distance N from the centreline of the first trench to the centreline of the next trench. Use the chart on previous page to find the right distance N for your pool. (Im- portant Note : The 12 x 18 pool has only one trench per side; the 15 x 24 pool has two trenches per side; the 12 x 24, 15 x 30 and 18 x 33 pools all have three trenches per side.) d. Place another stake in the ground on the edge of the cleared area at distance N, under- neath the string added in step 5(c). e. Repeat steps (a) to (d) for the other side of your pool. f. Tie a string between each pair of stakes on opposite sides of the cleared area (the stakes added in steps (b) and (d), above) to mark the centreline of the trenches. g. Mark the centrelines along each string with the can of spray paint. h. Recheck your measurements. Make sure the distances M and N exactly match the distances given in the chart above (see also diagram 26) and that the centrelines for the trenches are exactly parallel.
  • Page 19 j. Carefully dig out each patio stone trench. Hint: Stabilizer or equivalent Measure from must be used to backfill the centreline the patio stone trenches. painted on the ground and the line between the stakes. Do not dig the trenches too large or too deep; the ground around the edges of eacth trench must remain firm and un- disturbed. k. Temporarily replace the strings removed in step (i) to check that the trenches are exactly parallel. Remove the strings again when you are fin- ished. l. Spread a layer of crushed limestone (or equivalent) 1" (25 mm) thick into the bottom of the of each trench. Pack firmly. m. Place a concrete patio stone 12" x 12" square x 2" thick (30 x 30 x 5 cm) into each trench, on top of the lime- stone layer. Make sure it is level and positioned correctly.
  • Page 20 Parts List and Overview of Buttress Assembly Inside of Pool KEY Part Name KEY Part Name Upright Hardware bag,1 per set of buttresses; includes; Diagonal 1/4 "-20NC serrated flange hex bolt 16 Diagonal bracket No.12x1/2" self-tapping screw, pan head Phillips Strap 1/4"-20NC x 3/4" hex bolt Hold down plate 1/4"-20NC x 2-1/4" hex head bolt Curved bottom rail Base plate Top plate Rail Support Base plate 1-16 No Diving or Jumping. Observe all Safety Rules.
  • Page 21 1-17 No Diving or Jumping. Observe all Safety Rules.
  • Page 22 Strap Preparation for the Buttresses a. Gently flatten any kinks or bends out of the straps (key 8). b. Lay the strap across the levelled area for the pool as shown in diagram 30. Centre the strap over the patio stone as shown in diagram 30. Space the end of the strap 2-1/4" (6 cm) from the outside edge of the patio stone. c. Fasten one diagonal bracket (key 4) to the strap (key 8) using four 3/4" long bolts (key 21) and nuts (key 10). Make sure the angled part of the bracket is facing the correct direction as shown in diagram 32. The surface that the diagonal bracket is fastened to will be the top of the strap. d. Repeat steps (a) to (c) for the other end of the strap. e. Repeat steps (a) to (d) for the other straps. 1-18 No Diving or Jumping. Observe all Safety Rules.
  • Page 23 8. Installing the Upright a. Using a straight edge (you can use one of the hold down plates), drag along the top edge of the strap to ensure the ground is exactly even and level with the strap (the area 24" (61 cm) beyond each side of the strap must be level too). If it is not level, spread some crushed limestone (or equivalent) on the ground. Stand on the strap and tamp it down hard with a tamping tool. Verify the ground is level to the strap by running the straight edge along the top edge of the strap. Repeat this step until the ground is level. b. Gently lift the strap and insert four 3/4" long bolts (key 21) into the holes closest to the centre of the pool. Ensure the bolt heads are facing the ground. Lay the strap back down on the ground and place the hold down plate and base plate (as shown in diagram 36) over the bolts protruding from the strap and fasten the nuts to the bolts and tighten. 1-19 No Diving or Jumping. Observe all Safety Rules.
  • Page 24 c. Fasten one upright (key 1) to the base plate using three 3/4" long bolts (key 21) and nuts (key 10). Make sure the bottom end of the upright is fastened to the base plate. The bottom end of the upright has three large holes Caution: Failure to properly which are used to fasten to the base install and tighten all of plate. the bolts and nuts may void the warranty on your pool. d. When you come to section 2, you will install the bottom rails, linking them to the buttresses. Make sure now that there is approximately a 1/16" (2 mm) gap under the tab at the bottom of each upright so the bottom rails slide on easily. e. Repeat steps (a) to (d) for the other side of the pool. 9. Install the Diagonals a. Hold one diagonal brace (key 2) ap- proximately horizontal, insert the four tabs at the end of the diagonal into the slots in the upright (key 1) (see diagram 39). b. Pull upward on the inserted end of the diagonal to make the tabs slide up and lock into position in the slots. At Important: the same time, swing the other end of Ensure all four tabs at...
  • Page 25 Very important: as you swing the diagonal down, make sure you apply constant upward pressure on the end of the diagonal brace with the tabs to ensure they stay fully locked in position in the slots. c. Fasten the bottom end of the diagonal brace to the diagonal bracket (key 4) with two 2-1/4" (57 mm) bolts (key 26) and nuts (key 10). Do not overtighten the bolts. They only need to be snug enough to ensure a secure fit (see diagram 42). d. Repeat steps (a) to (c) for the other side of the pool. e. Repeat steps (7) to (9) for the rest of the buttresses. 10. Buttress Location Verification a. Tie strings between stakes (D) and (E) and between (F) and (G). These will be used as a reference to make sure the buttresses are exactly lined up with each other. Stand at each corner of the pool and check the alignment of the buttresses with the strings. b. Jump to Section 2 and complete steps 1(a) and (b). This will allow you to install the bottom buttress rails, ensur- ing the correct distance between the buttresses. Important: complete only steps 1(a) to (c) for now, and then continue with step 11 below; you will complete the rest of Section 2 later. 11. Fill in the Hold Down Plates a. Standing on the hold down plate, in- sert material into all open voids on the outside edges of the hold down plates until they are full. These voids are the open areas between the ground and the top edges of the hold down plate. Important: This will prevent any low spots from After the ends of the forming around the hold down plates...
  • Page 26 Important: Make sure each hold down plate lies completely flat. The hold down plate must lie flat or it may lift and damage the pool liner after the pool is filled with water. b. Repeat step (a) for the other hold down plates. 12. Remove the strings and stakes a. Make sure all of the strings and stakes (except stakes (A) and (B)) are removed from the entire pool area and fill in any holes with crushed limestone (or equivalent). Leave stakes (A) and (B) in place for now; they will be used later to centre the pool wall. b. Measure the two intersecting axes to ensure that the two straight sections are parallel. 1-22 No Diving or Jumping. Observe all Safety Rules.
  • Page 27 12 x 18 Footprint NLR-1510139 NLR-1440335 1-23 No Diving or Jumping. Observe all Safety Rules.
  • Page 28 12 x 24 Footprint NLR-1510139 NLR-1440335 NLR-1510139 NLR-1440335 NLR-1510139 NLR-1440335 1-24 No Diving or Jumping. Observe all Safety Rules.
  • Page 29 15 x 24 Footprint NLR-1510140 NLR-1510140 NLR-1440335 NLR-1510140 NLR-1510140 NLR-1440335 1-25 No Diving or Jumping. Observe all Safety Rules.
  • Page 30 15 x 30 Footprint 15'-0" NLR-1510140 NLR-1510140 NLR-1510140 NLR-1440335 NLR-1510140 NLR-1510140 NLR-1510140 NLR-1440335 NLR-1510140 NLR-1510140 NLR-1510140 NLR-1440335 1-26 No Diving or Jumping. Observe all Safety Rules.
  • Page 31 18 x 33 Footprint NLR-1510141 NLR-1510141 NLR-1440335 NLR-1510141 NLR-1510141 NLR-1440335 NLR-1510141 NLR-1510141 NLR-1440335 1-27 No Diving or Jumping. Observe all Safety Rules.
  • Page 32 No Diving or Jumping. Observe all Safety Rules.
  • Page 33 Pool Component Installation Manual ection Assembling the Pool Base & Side Buttresses 1. Install the Curved Bottom Rails a. Each pool uses two, three or four different types of curved bottom rails (key 13). The rails are colour coded or stamped with a part number. Use the chart below to choose the types and quantities of bottom rails for your pool (part numbers are shown in brackets under each colour).
  • Page 34 b. The pool has been supplied with resin rail supports. If you have a 12 x 18 (3,66m x 5,49m) pool proceed to Hint: step (d). For all other pools slide When measuring the distance to the face of the resin rail support to the middle of each base plate, use a the buttress bottom rail as shown in piece of string longer...
  • Page 35 Important: make sure you slide the rail into the notch so the closed, square part of the rail is in the notch, not Note: the open groove part of the rail (see If you want, the patio stones around the round diagrams 7 and 8).
  • Page 36 j. Use a carpenter’s level as you install each curved bottom rail to make sure it is level. k. Remove all the wooden stakes from the ground. 2. Spread out Brick Sand/Stabilizer a. Make sure any screw or bolt heads Remember: Spread brick sand/sta- that are to be covered with sand or...
  • Page 37 Pool Component Installation Manual ection Assembling the Pool Wall & Liner A. Assemble your Pool Wall Hint: This section is for Round and Oval pools (ROUND POOLS ARE SHOWN). Bring the following items onto the pool foundation 1. Set the Pool Wall in place before you start uncoiling the pool wall: the pool a.
  • Page 38 d. The slotted tubes (Omega Stabilizer) are colour coded or stamped with a part number. Use the chart below to choose the types and quantities of slotted tubes for Hint: Using a 2" (5 cm) piece your pool (part nos. are shown in brackets under each colour). Set lengths of slot- of duct tape, tape the ends ted tube onto the top edge of the wall as you uncoil it and join the slotted tubes with of the 6"...
  • Page 39 NOTE: We also suggest installing vinyl-covered hooks and rope to hold the wall steady. e. Work around the foundation until the entire pool wall is uncoiled into the bottom rails and the top edge is cov- ered with the omega stabilizer and connectors (and beaded liner retain- ers if you have a beaded pool liner) 2.
  • Page 40 4. Make a Cove a. If you are using sand, bank the sand against the wall to form a cove of 3” to 6” (7.5cm to 15cm) high and 8” to 12” (20cm to 30cm) wide at ground Remember: level. This will prevent the liner from The cove is an important creeping under the wall, and it will part of the pool structure.
  • Page 41 e. A vacuum cleaner can later be used to remove the air from between the liner and the wall. This technique enables you to remove folds in the liner. However the following precau- tions should be taken: Do not use an industrial vacuum cleaner which could be too powerful.
  • Page 42 B. Install your Pool Liner 1. Set the liner in place a. Open the carton. Do not use any- thing sharp to open the carton. b. Unpack and unfold the liner and spread it out in the sun to warm it up.
  • Page 43 2. Fasten the Liner in place (Overlap Liner only) a. Starting at the liner wall seam, Important: This hang the liner over the wall mak- step applies only if ing sure that the seam is straight up and down, perpendicular to the you have an Over- floor. (Remove stabilizers gradually lap Liner.
  • Page 44 3. Fasten the Liner in place (HUNG/J or V-BEAD LINER ONLY) a. With a V-Bead liner you will not use the plastic coping strips that are packed in the parts carton of your pool. You can discard those pieces, if they are included, as they only ap- ply to pools with overlap liners.
  • Page 45 4. Fasten the liner place (BEADLOCK/SNAPBEAD LINER ONLY) a. With a snap bead liner you will not use the plastic coping strips that are packed in the parts carton of many pools. You can discard those pieces (if they are included). Instead, you should have received a beaded liner track (referred to as a “coping bead receiver”...
  • Page 46 No Diving or Jumping. Observe all Safety Rules.
  • Page 47 Pool Component Installation Manual ection Installing the Top Rails & Verticals A. Attach your Uprights and Top Ledges (SUNRAY) 1. Continue filling your Pool a. Continue filling your pool with water. Do not put in more than 12" (30 cm) of water until the top rails and vertical columns are all attached. b. Keep working on the top rails and vertical columns while the pool fills. • See the drawing on the next page for an overview of all the parts used to install the verticals, top rails and top connectors. 2. Install the Uprights and Ledges a. Line up the bottom of one vertical column (key 1) with the tab on one base plate (key 2). The tab must be on the outside of the vertical column. b. Line up the screw holes and fasten with one self-tapping screw (key 3). c. Place a top connector (key 4) over the top edge of the pool wall (key 5) with the tab on the outside of the pool. Line up the hole in the tab with the screw hole near the top of Hint: Use the ridges in the the vertical column. The tab must be...
  • Page 48 Overview of Vertical, Top Rail and Top Connector Assembly g. Make the pool settle into a perfect circle by pushing the top of the pool wall vigorously inward at each ver- tical (this will help make the bottom Important: of the pool wall shift into a perfect The pool wall may circle). bulge and shift a little while filling with water. This is normal. Caution: Before anyone uses your pool, read and follow all the Safety Rules in Section 1. This pool is not for diving or jumping. No Diving or Jumping. Observe all Safety Rules.
  • Page 49 B. Fill your Pool with Water 1. Finish filling the pool a. Turn off the vacuum and carefully remove it from the pool. b. Fill the pool with water to 2” (5cm) below the lowest open- ing. Make sure you remove any creases from the liner in the bottom of the pool before the water level gets too high. c. While the pool is filling, remove the nails that were holding Caution: the bottom rails in place. Before making any openings in the liner, fill the pool d. Your pool is now installed. You must now install the filter with 60cm (24”) of and pump, the skimmer and water return inlet.Please follow water to stretch the liner fully. When filling the installation instructions that come with these products. your pool, begin with a garden hose until there is about 30cm...
  • Page 50 No Diving or Jumping. Observe all Safety Rules.