ECO SPARK 30 Installation Manual

Solar pool heating

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Magen eco-Spark

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Summary of Contents for ECO SPARK eco SPARK 30

Page 2: Table Of Contents
Table of Contents TABLE OF CONTENTS PREFACE ..................................5 Overview ..................................5 Safety precautions and regulations ..........................5 Transport and handling ..............................6 Lightning protection ..............................6 Definitions of terms used in this document ........................7 Modules/panels/banks ..............................7 Dimensions & specifications ............................8 Maximum operation pressure ............................
Page 3 Table of Contents INSTALLATION ................................21 Connecting panels together ............................21 Connecting across a large obstruction ........................... 24 Fixing panels to a sloping roof ............................24 Mounting panels using S roof mounting pads ........................ 25 Fixing panels to a flat roof .............................. 27 Pipes connections - CPVC Cementing ..........................
Page 4 Table of Contents Table of Figures Figure 1: Sample collector system ........................11 Figure 2: Sample mouting rack .......................... 12 Figure 3: PPC (Plastic Panel Connector) Set....................... 14 Figure 4: Ends of a bank ............................ 14 Figure 5: Connecting across an obstruction ...................... 24 Figure 6: Mounting with S Roof Mounting Pad Set ...................
Page 5: Preface
Preface Overview PREFACE ® ECO-SPARK SOLAR POOL PANELS ARE MANUFACTURED UTILIZING STATE-OF-THE-ART TECHNOLOGY ® AND PRODUCTION TECHNIQUES. ECO-SPARK COLLECTORS ARE SLEEK AND SIMPLE, YET THE PATENTED OVERMOLDING DESIGN MAKES THEM DURABLE ENOUGH TO LAST A LIFETIME. CORRECT INSTALLATION ® IS ESSENTIAL TO THE OVERALL SUCCESS OF THE SYSTEM. INSTALLED CORRECTLY, AN ECO-SPARK SYSTEM IS PRACTICALLY MAINTENANCE FREE, AS IT TAPS SOLAR HEAT YEAR AFTER YEAR.
Page 6: Transport And Handling
Preface Safety precautions and regulations ® Important: Avoid walking over the eco-Spark collectors! Wherever possible, the system should be installed so that all parts of it are accessible. Warning! Water in the collector can reach high temperatures (up to 90°C, 194°F)! Take caution while handling the collector to avoid burns.
Page 7: Definitions Of Terms Used In This Document
Preface Definitions of terms used in this document DEFINITIONS OF TERMS USED IN THIS DOCUMENT Module – 39 individual tubes connected to 30 cm (1') wide manifold on both ends. Each module is encased in transparent multi-layer polycarbonate plate. Panel – Four (4) modules welded to one another at the manufacturing facility. The collector absorbs the sun rays and transforms them into thermal energy.
Page 8: Dimensions & Specifications
Preface Maximum operation pressure Maximum operation pressure Bank – a structure made of several panels joined together with Magen eco-Energy's (MEE) designated Plastic Pipe Connectors (PPC). DIMENSIONS & SPECIFICATIONS Model Metric Units Spark 40 Spark 30 US Units Spark 40 Spark 30 M.E.E.
Page 9: Designing Your System
DESIGNING YOUR SYSTEM THE SOLAR SYSTEM LAYOUT DESIGNING YOUR SYSTEM This chapter describes the factors you need to take into account when designing your system, and the process planning of the systems' structure. During all stages of the design and construction keep in mind that you want to produce a system for the customer that will be as efficient and as AESTHETICALLY PLEASING as possible.
Page 10: Tilt
DESIGNING YOUR SYSTEM Tilt TILT Be sure the planned position of the collector panels allows for them to drain naturally when the pool pump shuts off. Tip: The “ideal” angle for maximum solar collection should be similar to the local latitude or up to 15 higher.
Page 11: Sample Collector System
DESIGNING YOUR SYSTEM Sample collector system SAMPLE COLLECTOR SYSTEM Figure 1: Sample collector system Note: example illustrated above does not allow for natural water drainage and is not suitable for colder regions with freezing conditions. 1. Feed line climbing to far point from pump house. 2.
Page 12: Mounting Racks
DESIGNING YOUR SYSTEM Mounting racks MOUNTING RACKS Important: The collector must be supported and lying on a rigid surface. It is not a self-supported unit. Wherever the system is installed, both headers should be elevated 2.5 cm (1") to 5 cm (2") above the roof/ground, by using stainless steel/wooden profiles.
Page 13: Parts And Tools
Parts and tools Mounting racks PARTS AND TOOLS Once you know the layout of your solar collector system, and how many panels/modules you ® require, this chapter will help you calculate which eco-Spark panels and other fittings you will need to complete your installation. This chapter deals with the following three categories: ®...
Page 14: Fittings And Accessories
Parts and tools fittings and accessories FITTINGS AND ACCESSORIES ® This section summarizes the four basic types of connections to and between eco-Spark panels, using ® eco-Spark fittings. CONNECTING BETWEEN PANELS/MODULES To connect one panel to another or a panel to a module, you need a PPC connector set. This consists of a clamp top and bottom, a rubber gasket, a latch and a latch lock.
Page 15: Securing Panels To The Roof
Parts and tools Pipes and other fittings SECURING PANELS TO THE ROOF Panels are secured to the roof using S Roof Mounting Pads (Cat. Num.1203100). As a general rule of thumb allow 3 pads per panel, 2 at the upper end and one at the bottom. For steep roofs or windy regions, use 4 units per panel, 2 at the upper end and 2 at the lower end.
Page 16: Other Fittings
Parts and tools Pipes and other fittings OTHER FITTINGS Depending on your specific job, you will need various other plumbing items and materials such as: Valves, stainless steel lag bolts, silicone or polyurethane caulk, silicone spray, galvanized pipe straps, black electrical wire ties, electrical wire nuts, 18ga-22ga sensor wire, 14ga-16ga electrical wire with ground, Teflon tape, concrete anchors and screws, electrical conduit, etc.
Page 17: Hydraulics
hydraulics Panel configurations HYDRAULICS This chapter deals with the hydraulics that demands consideration before installation. PANEL CONFIGURATIONS Before you can start constructing the system you have designed, you must consider how the banks will be connected together. You must also take into account the maximum number of panels allowed per bank, as shown below.
Page 18: Plumbing
hydraulics Plumbing BANKS IN SERIES ROOF TILT FEED RETURN BANKS IN SERIE BANKS IN SERIES RETURN FEED ROOF TILT SINGLE BANK SPLIT FEED RETURN ROOF TILT FEED PLUMBING WATER INLET /OUTLET  Inlets are always connected to a lower end of the bank; Outlets to the opposite upper corner (diagonally).
Page 19: Pipe Diameter
hydraulics Plumbing PIPE DIAMETER It is important that all plumbing connected to the system uses a diameter of pipe appropriate to the size of your solar array. Insufficient pipe diameter will unnecessarily restrict water flow to the panels. Use the following as a guide: Table 3: Recommended pipe diameters Flow Rate...
Page 20: Pump Power
hydraulics Plumbing PUMP POWER ® The power of the swimming pool filtration pump must be adequate to supply the eco-Spark system with enough flow & pressure to provide the recommended parameters. These recommended rates are detailed in the table below: Table 4: Recommended flow rate through the panels Panel type Recommended Flow per Panel...
Page 21: Installation
Installation Connecting panels together INSTALLATION This chapter describes four basic installation processes:  Connecting panels together  Securing panels to the roof (sloping or flat)  Connecting panels to piping Tip: It is highly recommended to visit the site BEFORE installation day. Inspecting the site after you have planned the installation layout is of great help in foreseeing and solving possible problems.
Page 22 Installation Connecting panels together Connect the two headers by inserting the rubber gasket (O-ring) into the opposite header groove and fitting the ends of both headers into the PPC (plastic panel clamp). Important: Make sure that the gasket sits snugly in the grooves of both headers, and is not squashed or pinched between the headers, as this could result in leaking.
Page 23 Installation Connecting panels together Lock the two halves of the clamp together using the latch (120211P). Do this by sliding the wide end of the cone shaped latch over the thin end of the PPC assembly. Use Channel lock pliers to tighten the latch grip by squeezing it with moderate force until you hear a 'click' sound and it seats flush so it cannot slide out of its position.
Page 24: Connecting Across A Large Obstruction
Installation Connecting across a large obstruction CONNECTING ACROSS A LARGE OBSTRUCTION For obstructions, you need to bypass the obstacle using extension pipes between the manifolds. Figure 5: Connecting across an obstruction When connecting two panels/modules together across a large obstacle you need: ...
Page 25: Mounting Panels Using S Roof Mounting Pads
Installation Mounting panels using S roof mounting pads 2. It is recommended to lock the center of each bank in place, so as to spread thermal expansion and contraction evenly between both sides. To lock the center panel of a bank, position the mounting pads on that panel adjacent to the left and right of one of the header ribs.
Page 26 Installation Mounting panels using S roof mounting pads Screw the Top S Mounting pads to Thread the bottom S Mounting pads into the profile. the headers and connect them to the profile. Pay attention to the ambient temperature and position the slider over the track and grid closest to the graphic mark that best describes the weather accurately.
Page 27: Fixing Panels To A Flat Roof
Installation fixing panels to a flat roof Verify that all lag bolts are secured and that adequate sealant has been used to prevent any roof leaks where they are attached. Ensure that all four corners of the bank are securely fastened to the roof. Figure 7: Correct installation of S Roof Mouting Pad Set Important: Position the Slider over the track and grid on the bottom S mounting pad according to the current ambient weather.
Page 28: Pipes Connections - Cpvc Cementing
Installation PIPES CONNECTIONS - CPVC Cementing PIPES CONNECTIONS - CPVC CEMENTING Important: Pipe Adaptors must be made from identical material as the pipelines; otherwise connections will not last long and will shortly dismantle. Part CPVC pipe adaptor (mm) CPVC pipe adaptor (inch) MEE Cat.
Page 29: Pipes Connections - Pex Welding
Installation PIPES CONNECTIONS - pex welding Hold it in position for 5–10 seconds (longer when ambient temperatures are low) to allow the cement to set slightly. Wipe away any excess cement. Tip: By taping the cans of CPVC cleaner and CPVC Cement together you can reduce the risk of them tipping over and spilling.
Page 30 Installation PIPES CONNECTIONS - pex welding Measure and mark the length of the Mark the area that will require part you will be using. scrapping. Scrap the area until the lines you just Mark how much of the pipe should be marked disappear.
Page 31: Pipes Connections - Ppr Welding
Installation PIPES CONNECTIONS - ppr welding PIPES CONNECTIONS - PPR WELDING Before welding the pipes, be sure to Hold firmly until both ends are clean the contact areas thoroughly. sufficiently warm. Attach both the PPR pipe and the high temperature pipe adaptor machine.
Page 32: Connecting To Existing Equipment
CONNECTION TO EXISTING EQUIPMENT Feed and return lines CONNECTION TO EXISTING EQUIPMENT This chapter describes the standard (and most common) method of running the pipelines from the feed and return lines to the existing ground level equipment. Some installations may require a more creative approach.
Page 33: Connecting To Existing Filtration System Plumbing Guidelines
CONNECTION TO EXISTING EQUIPMENT Connecting to existing filtration system Plumbing guidelines CONNECTING TO EXISTING FILTRATION SYSTEM...
Page 34 CONNECTION TO EXISTING EQUIPMENT Connecting to existing filtration system Plumbing guidelines PLUMBING GUIDELINES ® The figure in the former page illustrates how a typical eco-Spark solar pool heating system is connected to a pools' plumbing. Even if your system is not identical to the one shown, the illustration can help you understand the flow of water from the pool, through the pump, filter, solar system and back to the pool.
Page 35: Connect With The Filtration System
CONNECTION TO EXISTING EQUIPMENT Connecting to existing filtration system Plumbing guidelines CONNECT WITH THE FILTRATION SYSTEM 1. Study the plumbing after the filter and decide where you are going to install the union check valve and the “T” fitting for the solar system entrance. If you have auxiliary equipment, you may need to re-plumb a portion of your existing plumbing so this equipment is located after the eco-Spark®...
Page 36: Running Feed And Return Lines To Ground Level
CONNECTION TO EXISTING EQUIPMENT Connecting to existing filtration system Plumbing guidelines RUNNING FEED AND RETURN LINES TO GROUND LEVEL To run feed and return lines to ground level: Connect the appropriate sized 90° elbow to the return line stub, facing down towards the bottom header.
Page 37: Automatic Systems (Private & Public Pools)
CONNECTION TO EXISTING EQUIPMENT Automatic systems (private & public pools) AUTOMATIC SYSTEMS (PRIVATE & PUBLIC POOLS) The basic difference between the manual system just outlined and an automatic system is the use of a motorized 3-way valve, which is controlled by two sensors. In cloudy weather conditions the connection with the pool automatically shuts off to maintain the warmest temperature possible.
Page 38 CONNECTION TO EXISTING EQUIPMENT Automatic systems (private & public pools) Public pool basic plumbing BACKUP HEATER EXISTING PIPING BOOSTER ADDITIONAL PUMP + PIPING CONTROLLED VALVE POOL PUMP FILTER The additional booster pump should be installed after the filter, using a “T” joint on the main filtration pipe. The automatic control commands both the booster pump and the 2 way valve after it.
Page 39: Operation
operation Before letting water into the system OPERATION If you have carefully followed the steps in this manual, you now have an efficient, professional looking eco- ® Spark solar pool heating system. This chapter deals with the final checks before you let water into the system, high pressure testing of the system, and turning the system on and off.
Page 40: Turning The System On (Manual Systems)
operation Turning the system on (manual systems) TURNING THE SYSTEM ON (MANUAL SYSTEMS) Turn the pool pump off. Turn the 3-way valve so the “closed” indicator points towards the pool side of the valve. Be sure that the ball valves on the feed and return lines are open. Turn the pool pump on.
Page 41: Turning The System Off (Automatic Systems)
MAINTENANCE Turning the system off (automatic systems) TURNING THE SYSTEM OFF (AUTOMATIC SYSTEMS) 1. Switch the system's controller off. 2. To drain the water from the system, open the outlet valve (see red valve #4 on page 33) and let the water drain from the system. Leave the valve open as long as the system is not in use.
Page 42: Troublshooting
Troublshooting Turning the system off (automatic systems) TROUBLSHOOTING This section will assist in identifying and solving problems as quickly and as effectively as possible THERE ARE AIR BUBBLES IN THE POOL WHEN THE SOLAR HEATER IS OPERATING Diagnosis #1: There might be air coming into the pump through an air leak on the suction side of the pump due to the pump working harder to move the water through the solar system.
Page 43 Troublshooting Turning the system off (automatic systems) If the system is a double row or a single row split feed array and there is adequate flow, install a Ball Valve on the return side of the set of panels that are the coolest, throttle back the flow through these panels and force more water through the warmer panels.
Page 44: Disabling A Damaged Riser Tube
Disabling a damaged riser tube Turning the system off (automatic systems) DISABLING A DAMAGED RISER TUBE In the event of a riser getting damaged and leaking, one of the advantages of the eco-Spark® collectors is the ease with which the leaking riser can be disabled, the leak repaired, and the disabled riser attached to maintain the uniform appearance of the panel.
Page 45 Disabling a damaged riser tube Turning the system off (automatic systems) Using a 6 mm chisel, and holding the flat side of the chisel towards the header, cut through the damaged riser, flush against the header. A round hole is created in the manifold header. Spray the rubber sleeve with a silicone spray lubricant and pull it over the small metal pin of the repair...
Page 46 Disabling a damaged riser tube Turning the system off (automatic systems) Push the plastic repair plug all the way down into the repair sleeve. You may use the rear part of the handle to push it firmly into the sleeve. The hole is now plugged and will not leak.
Page 47: Direct Pre-Heating
eco-spark® for pre-heating Direct pre-heating ® ® eco-SPARK solar collectors are perfect for pre-heating systems. There are two types of pre-heating ® systems that eco-SPARK will provide the most cost-effective solution: 1. Direct pre-heating 2. Storage tank circulation system There are many configurations for these systems; design the system so it meets users' requirements. Important! System MUST be designed by a professional engineer.
Page 48 eco-spark® for pre-heating Direct pre-heating 1. Fresh water feeds into the solar panels at grid pressure (max. 4 bar/60 psi) whenever there is demand. 2. Differential controller operates the system according to the temperature sensors. A 3-way-valve diverts the feed water either to the solar system or the bypass for the auxiliary heating system.
Page 49: Solar Hot Water Storage Tank
eco-spark® for pre-heating Solar hot water storage tank SOLAR HOT WATER STORAGE TANK ® The eco-SPARK system can be installed as an open or closed loop system and circulates the water in the storage tank. The system is in installed on the feed line to the current conventional heating system. The feed enters the storage tank.
Page 50 eco-spark® for pre-heating Solar hot water storage tank 10. Hot water distribution station for users. System must be designed by a professional engineer considering the following: Flow rates The flow in each panel should be an average of 300 l/h (1.3 gpm). Bank arrangements should not exceed more than 3 banks in one series (consider specific conditions to determine number of banks).