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EcoOnline Vertex Self-Prime Installation & User Manual

Pool & spa solar heating system
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EcoOnline - Vertex™ Self-Prime
Pool & Spa Solar Heating System
Installation & User Manual – Revised 24/08/2019
© Copyright 2019 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 2019 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 Self-Prime

  • Page 1 EcoOnline - Vertex™ Self-Prime Pool & Spa Solar Heating System Installation & User Manual – Revised 24/08/2019 Optex Solar Pty. Ltd. ABN: 88 128 228 884 www.EcoOnline.com.au email: info@EcoOnline.com.au © Copyright 2019 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 For Suction Line “Over the Top” Systems 22.1 Installation of the By-Pass Ports and Line 23 “Over the Top”...

  • 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 6 Spa Chemistry Compatibility Guide This system is not compatible with bromide chlorination, hydrochloric acid use and/or acidic pool/spa water (pH less than 7.2). Sodium Carbonate must be added to protect the system from acidic pH (<7).
  • Page 8 7 Roof Type Compatibility Guide The average air gap distance between the mounted collector and roof structure has a strong influence on wind loadings. If panels are to be installed on a roof then the following should be observed to limit wind uplift potential. 1) Installed panels should lay flat close to the roof structure.

  • 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 × 25cm length perforated 316 stainless band Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 9 ©...
  • Page 10 12V Solar Pump Kit 1 × 12V Solar pump (max 3.5 pump height) with 1 × 40W or 60W Solar panel with PVC wire, connector connector, 1 × 25mm PVC Bubble chamber, 1 × 20mm and under-temperature thermostat Strainer to Pump SpaFlex line, 1 × Vertex Non-return Vertex Base Plumbing Kit Components 1 ×...
  • Page 11 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 12: Roof Mounting

    10.2 Roof Mounting If installing the panels on a roof you will also require the following extra items. 32mm x 32mm x 3mm Aluminium angle 4mm stainless steel cable & four cable ties per row These are available in any plumbing store. The aluminium angle is available from Capral Ltd. or Ullrich Aluminium Pty.
  • Page 13 12 Safety When Working at Heights WHEN WORKING AT HEIGHTS - SAFETY COMES FIRST. A person can easily fall off a ladder or roof and be seriously injured. For installations on a roof pitch greater than 22° and/or a double story house we strongly recommend a highly competent professional installer install your solar collector array.
  • Page 14 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 15 Check that the wires in the connector aren’t twisted internally and the positive and negative connections line up. 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 15 ©...
  • Page 16 15 Collector Array Configuration We strongly recommend a metal hack saw when cutting PVC pipe to reduce shaving size as the pump has a very fine rotor clearance. To make sure all air bubbles are evacuated upon filling, collectors MUST be installed with a minimum recommended pitch of 5˚.
  • Page 17 15.1 Array Configurations Not Recommend 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 18 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 19 17.1 Aluminium Angle Mounting Options 17.1 Thermal Expansion Gaps for Aluminium Channels 17.2 Metal Roof Screw Selection and Method Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 19 © Copyright 2019 Optex Solar Pty Ltd. All rights strictly reserved.
  • Page 20 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 21 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 22 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 23 20.2 Single or Multi-Row Metal Roof Fixings Wind Region A Vertex Solar™ Pool & Spa Heating System -- Installation & User Manual Page 23 © Copyright 2019 Optex Solar Pty Ltd. All rights strictly reserved.
  • Page 24 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 24 ©...
  • Page 25 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 26 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 27 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 28 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 29 22 For Suction Line “Over the Top” Systems The below suction/pump/filter/by-pass assembly configuration MUST be followed exactly. Take particular note of the by-pass port levels, i.e. the bubble chamber port level A must be ~50mm above the C ports while the by-pass port B on the suction lies somewhere in between.
  • Page 30 23 “Over the Top” Return Line Configuration You CANNOT rely on a person to remember to put back the return line after pool/spa use, people may get distracted in the process or it may be pulled out by children (if the spa is accessible) or persons/animals/events.
  • Page 31 24 Special Plumbing Situations 24.1 For Systems with Pump Assembly Mounted Well above the Water Level If you have a very long above ground run of suction line then upon start up you may see the water level in the buffer chamber drop down to the top of the clear section of the filter, if it drops further the pump will start to churn and struggle to clear an air/water mixture.
  • Page 32 24.2 For Systems with Standard Suction Ports and Pump Assembly below the Water Level 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. 24.3 For Systems with below Water Level Collectors Vertex Solar™...
  • Page 33 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 25.1 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 PVC 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 35 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 36 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 37 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 38 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 39 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. If you have a long length of suction line above the water level then the waterline in the buffer chamber may drop to the visible section during start up.
  • Page 40 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 41: Service And Maintenance Schedule

    Downloads Page: www.EcoOnline.com.au/downloads The system strainer should be cleaned regularly depending on spa use. When cleaning the strainer it is important not to let debris get into the buffer chamber - any such debris will go straight into the pump the next time the system starts up.

  • Page 42: 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...