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EcoOnline Vertex Flood-Prime Installation & User Manual

Solar pool & spa heating system
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EcoOnline - Vertex™ Flood-Prime
Solar Pool & Spa Heating System
Installation & User Manual – Revised 14/11/2021
© Copyright 2021 Optex Solar Pty Ltd. All rights strictly reserved. This publication is protected by copyright law
and unless otherwise specified is for your personal and non-commercial use only. No part of this publication
may be reproduced or distributed by any process, electronic or otherwise, without the specific written
permission of Optex Solar Pty Ltd. Trademarks appearing in this manual are the sole property of Optex Solar
Pty Ltd or their respective owners. Nothing in this publication shall be construed as granting any express or
implied license to use any intellectual property of Optex Solar Pty Ltd otherwise than for personal and
non-commercial use only. Optex Solar Pty Ltd must not, to the full extent permitted by law, be held liable
for any claim, cost (including legal costs), damage, expense, loss (including fines, penalties, set-offs and
consequential loss) or liability arising from the use (or misuse) of any product described in this
publication, unless expressly provided otherwise in this publication. Information as well as any
products described in this publication are subject to change without notice.
Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual
© Copyright 2021 Optex Solar Pty Ltd. All rights strictly reserved.
Optex Solar Pty. Ltd.
ABN: 88 128 228 884
www.EcoOnline.com.au
email:
info@EcoOnline.com.au
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Summary of Contents for EcoOnline Vertex Flood-Prime

  • Page 1 EcoOnline - Vertex™ Flood-Prime Solar Pool & Spa Heating System Installation & User Manual – Revised 14/11/2021 Optex Solar Pty. Ltd. ABN: 88 128 228 884 www.EcoOnline.com.au email: info@EcoOnline.com.au © Copyright 2021 Optex Solar Pty Ltd. All rights strictly reserved. This publication is protected by copyright law and unless otherwise specified is for your personal and non-commercial use only.
  • Page 2 Contents Key Terms Pre-Installation Suitability & Safety Checklist Warranties System Sizing Guarantee Collector and Solar Pump Sizing Guide Spa Chemistry Compatibility Guide Roof Type Compatibility Guide Wind and Climate Considerations Included System Components 10 Additional Required Components (Not Supplied) 10.1 Ground Mounting Support Frame 10.2 Roof Mounting...
  • Page 3 21 Wind Proofing 21.1 Ultimate Peak Wind Loadings per Panel 21.2 Frequency of Extra Fixings for Different Regions 21.3 Wind Region Definitions 21.4 Terrain Category Definitions 21.5 Roof Edge Exclusions Zones 22 Plumbing Diagram 23 Suction Line / Pump / By-Pass Line / Bubble Chamber Configuration 23.1 Installation of the By-Pass Ports and Line 23.2...

  • Page 4: Key Terms

    Particular attention should be given to text contained in the following key terms. Please note EcoOnline has a strong product safety policy; do not install products without reading safety guidelines in the manual. Please report any product safety issues or near misses to info@EcoOnline.com.au no matter how trivial.
  • Page 5 2 Pre-Installation Suitability & Safety Checklist The following outlines mandatory suitability and safety requirements for installing a Vertex Solar™ heating system. Please read carefully, if any of the following requirements cannot be meet a Vertex system should NOT be purchased or installed.
  • Page 6 Sizing systems is difficult involving a lot of factors which we could get wrong. Hence in addition to the above Warranties EcoOnline offers a System Sizing Guarantee as follows. If we sized your system (or you use our online calculator) and you took our advice and you aren’t happy with the systems performance (heat output), then you can purchase up to 25% more panels originally supplied by EcoOnline up to two years after your original purchase and we will ship the items free of shipping charges.
  • Page 7 5 Collector and Solar Pump Sizing Guide An interactive collector and pump sizing calculator, for vinyl covered spas pools can be found on our website: www.ecoonline.com.au/covered-spa-heating-system-sizing-calculator for uncovered or blanket covered pools or swim spas please use the calculator here: www.ecoonline.com.au/uncovered-swim-spa-heating-system-sizing-calculator...
  • Page 8 ollector Panel orregated metal roof or le roof ollector bo om to roof valley air gap should perferably be less than (for gaps mm use Wind egion xings) Roof Type Peak to Valley Measure Recommendations Standard Corrugated Iron roof (Custom Orb) 17mm Use Respective Wind Region Fixings Relatively Flat Tile roof...

  • Page 9: Included System Components

    9 Included System Components Panel Kit (if purchased) 2 × 40mm reinforced silicon joiners 4 × Stainless steel hose clamps 1 × HDPE collector panel 6 × 316 stainless straps (black) 1 × 10cm length perforated 316 stainless band 12V Solar Pump Kit 1 ×...
  • Page 10 Safety Over-Temperature Thermostat Kit 2 × 25mm ID Armaflex pipe insulation 1 × 60mm ID Armaflex pipe insulation 1 × Aluminium U-channel 1 × 5m PVC Extension Wire 1 × Twin 40°C thermostats with 2m cord and positive disconnect connector 3 ×...

  • Page 11: Roof Mounting

    10 Additional Required Components (Not Supplied) 10.1 Ground Mounting Support Frame You may need to build a support frame for your collector array, if so you may require the following: • Two 70mm x 35mm 1.3m treated pine length per collector (lengths depend on mounting preferences) •...

  • Page 12: Required Tools

    11 Required Tools - Battery powered hand drill with 8mm Hex socket - Screwdriver with 8mm socket fitting - Clear silicon - Hack saw (metal blade to reduce PVC filing size) - PVC glue (Green pressure) - Level - Soldering iron - 3mm drill bit 12 Safety When Working at Heights WHEN WORKING AT HEIGHTS - SAFETY COMES FIRST.
  • Page 13 13 Choosing A Place to Install the Collector Array When choosing a location for your collector array you should consider the following in order of importance: 1. Shading - the collectors should receive no shading between the hours 10am to 4pm. 2.
  • Page 14 If it still won’t start please contact us at info@EcoOnline.com.au technical support. Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 14 ©...
  • Page 15 15 Collector Array Configurations To make sure all air bubbles are evacuated upon filling, collectors MUST be installed with a minimum recommended pitch of 5˚. Also ideally the top header pipe should have a 1 or 2° upward slope toward the top outlet return, such that the top outlet return corner of the collector array at the highest point.
  • Page 16 16 Roof Attachment Options Note the high thermal contraction and natural relaxation of HDPE: Collectors will contact (in length) by up to 10mm over time and 12mm thermally across temperature extremes. Hence any fixing means must account for an ultimate contraction of 22mm in length per panel. Key design principles when choosing a roof mounting means: 1) Consider the high thermal contraction of HDPE 2) Panels should be as low down on the roof as possible to prevent the wind from...
  • Page 17 17 Corrugated Metal Roof Aluminium Angle Mounting Options For metal roofs we recommend using a minimum screw fixing space of 600mm when fixing the aluminium angle. Depending on your wind loading (see “Wind Proofing” section), angle of install, you may require a higher density of fixings and/or a stronger Aluminium angle, if unsure please seek advice.
  • Page 18 17.3 Metal Roof Screw Selection and Method Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 18 © Copyright 2021 Optex Solar Pty Ltd. All rights strictly reserved.
  • Page 19 18 Collector Mounting Procedure Collectors will contact (in length) by up to 10mm over time and 12mm thermally for an ultimate contraction of 22mm in length per panel. For a two row array strapped between a top and bottom aluminium rail the total ultimate contraction is then 44mm. The top and bottom strap must have sufficient play to account for this ultimate contraction.
  • Page 20 19 Collector Array Plumbing Connections BEFORE CUTTING - put aside two collectors per row with undamaged end caps. For all remaining collectors cut the single end cap off using a sharp blade. Laceration hazard: Always cut away from your body and ensure no parts of the body are in front of the cutting blade.
  • Page 21 20 Roof Fixings When working with power or hand tools always follow the safety instructions. • Wear the recommended personal protective equipment, such as gloves, safety glasses, respiratory and hearing projection. • Make sure electrical cables are kept away from any water and from foreign objects which pose a potential cable severing or crushing hazard.
  • Page 22 20.2 Single or Multi-Row Metal Roof Fixings Wind Region A Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 22 © Copyright 2021 Optex Solar Pty Ltd. All rights strictly reserved.
  • Page 23 20.3 Single or Multi-Row Metal Roof Fixings for Wind Regions B & C NOTE: For single or multi-row arrays in wind regions B or C, aluminium L-angle MUST be run for the top and bottom of each row. Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 23 ©...
  • Page 24 20.4 Single or Multi-Row Tile Roof Fixings for Wind Region A & B For single or multi-row arrays in wind regions B, aluminium L-angle MUST be run for the top and bottom of each row. 20.5 Perforated Band Under-Tile Anchor Point (For Region B or Two row arrays) Vertex Solar™...
  • Page 25 Note, roof installation of these panels in Wind Region D is not recommended. This section provides general advice on wind loadings. If you have any doubt about your wind loadings please contact info@EcoOnline.com.au 21.1 Ultimate Peak Wind Loadings per Panel The following Tables specify the ultimate peak uplift any single panel can experience in a 1 in 500 year extreme storm or cyclone event according to Australian Standard 1170.2 - 2011 (Amend 2 Dec 2012).
  • Page 26 Note: Installations involving a second story roof or higher, or houses on hills, or panels mounted 50mm or greater above the roof structure have higher potential wind loadings. Please contact info@EcoOnline.com.au for ultimate wind loadings based on your details. 21.2 Frequency of Extra Fixings for Different Regions...
  • Page 27 21.4 Terrain Category Definitions • Terrain Category 1: Open terrain few obstructions. Example flat, treeless, poorly grassed plains. • Terrain Category 2: Open terrain with scattered obstructions having heights from 1 .5m to 5m, with at least two building type obstructions per hectare. Example farmland and cleared subdivisions with isolated trees. •...

  • Page 28: Plumbing Diagram

    22 Plumbing Diagram The installation of at least two Australian Standard approved suction outlet adapters, 600mm apart connected by a T-piece PVC plumbing is mandated for pools and spas. Due to the potential for hot water at the outlet on start-up, solar heating outlets shall not be connected to water features or waterfalls, or any other outlet(s) that are not permanently fixed underwater.
  • Page 29 23 Suction Line / Pump / By-Pass Line / Bubble Chamber Configuration The below suction/pump/by-pass line/bubble chamber mounting configuration MUST be followed exactly. Take particular note of the pump and strainer water level and orientation, the slope in the suction line and the position of by-pass line under the 25mm PVC pipe. Why? If air traps are present, air bubbles will accumulate in the system when the system drains down through the suction line.
  • Page 30 locking collar ONLY – DO NOT use silicon lube on any part of the grommet - water lubricant only. The by-pass line comes with a 3mm inner constriction encased in a clear PVC line. This may need cleaning at some point. Warm the PVC around the barb with hot water and twist, for easier removal from the barb 23.2 Suction Plumbing Configurations Not Allowed The guiding principle here is that all suction lines must automatically, fully and completely...
  • Page 31 24 Different Plumbing Situations 24.1 From Spa to Roof Collector Plumbing Setup The Vacuum Breaker valve should face vertically upward and be mounted just off the roof on the vertical supply line. Unscrew the top black air intake nozzle. Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 31 ©...
  • Page 32 24.2 From Spa to Ground Run to Roof Collector Plumbing Setup (Extra Vac Valve Required) The Vacuum Breaker valve should face vertically upward and be mounted just off the roof on the vertical supply line. Unscrew the top black air intake nozzle. If any part of the return line plumbing or return outlet port is installed far below the water line (greater than 0.5meters) then an extra Vertex vacuum beaker valve should be installed on the return line to remove the extra pump height created.
  • Page 33 24.3 From Spa to Ground Mounted Collector Plumbing Setup Below water level mounted collectors are allowed only in frost free areas, otherwise all collectors and plumbing lines must be frost tolerant. Collectors should not be mounted such that the lowest part is lower than 1m below the water line. Below water level mounted collectors are subject to much harsher conditions than collectors that drain down.
  • Page 34 25 Allowable Plumbing Variations U-bends in the supply line will not drain fully and hence prevent air communication between the vacuum release and the pump assembly and should be avoided if at all possible. Preferably, all parts of the suction line should be mounted and sloped such that water empties fully up to the bubble chamber when the system stops.
  • Page 35 25.1 Dual Pump Setups If your system came with dual pumps you can plumb them in vertically as shown or in a 45˚ configuration as shown in the previous section. For such dual pumps you’ll also need to purchase 3 extra PV bits; you can use 2 faucet take offs with a 20mm straight joiner or 2 faucet sockets with a 20mm PVC pipe for the interconnector between the pumps.
  • Page 36 26 Solar PV Panel Mounting The solar PV panel acts as a power source AND sun sensor for the thermal OKU collectors. Hence, the PV panel should be mounted at the same compass direction as the collector array, with the following exceptions: 1) For West or East facing thermal collector installations it is preferable that the PV panel face closer to NW or NE respectively.
  • Page 37 27 Installing the Over-Temperature Thermostat Important: If the area of your collector array is oversized for your pool/spa and/or you have a highly insulated/covered pool/spa - you will require a safety thermostat to prevent the potential overheating of your pool/spa. The thermostat assembly should always be installed on the higher temperature OUTLET (RETURN) SIDE of the collector array.
  • Page 38 Over-temperature thermostat assembly MUST be installed in a sheltered location away from rain and sun expose and in such a way that any water droplet condensation on pipes or wires cannot run inside the assembly. Adequate insulation of the Aluminium U-channel is required, otherwise the exposure of the U-channel to cooler external air may prevent the U-channel and hence the face of the thermostat from reaching the cut-off temperature.
  • Page 39 28 Connecting the Inline Over-Temperature Thermostat and Extension Wire The connectors should not be in a position such that they are continuously exposed to splashing spa water or rain ingress which can run down the cord and make its way inside the connector.
  • Page 40 29 Switching the System ON for the First Time We recommend you wait till a sunny day and follow this procedure: 1. After the under-temperature thermostat has turned ON, connect the pump which will start in 3secs. Listen to the pump start - after an initial purge of air the pump should run smooth. 2.
  • Page 41 30 Important Installation Check List Your installation must have the following elements, see manual. The top header pipe was installed with a 1 to 2° slope toward the outlet. Aluminium channel was laid top and bottom of the collector array as shown in the manual. Ultimate uplift wind loadings were considered and panels secured appropriately.

  • Page 42: Service And Maintenance Schedule

    Important: before carrying out any system maintenance you MUST check for any manual and or technical service bulletin updates and download the latest installation manual from our Downloads Page: www.EcoOnline.com.au/downloads The system strainer should be cleaned regularly depending on spa use. Annual...
  • Page 43 Fatigued, weathered, loose and/or corroded wiring or electrical connections poses a fire risk even at low voltage. 32.1 Collector Puncture Repair Procedure Drill out the puncture using a sharp drill bit (being careful not to drill into the opposite wall). Inject chlorine resistant pool silicon into the collector inner to create a ~10cm inner silicon disk plug.

  • Page 44: Troubleshooting

    * Check plumbing for blockages and/or air locks. You may need a midday below my arrays create a large temperature stronger pump for more flow. Else contact info@ecoonline.com.au preferred temperature differential triggering the over- on this issue. temperature thermostat early...