Installation/Owner Manual

SOLARHOT Pool Heating Installation

SOLARHOT

233 East Johnson St Suite O Cary, NC 27513

T 919 439 2387 F 919 573 0791

info@solarh2ot.com

http://www.solarhotusa.com

SOLARHOT

Table of Contents
GETTING STARTED

THINGS TO REMEMBER

INSTALLATION KITS AND COMPONENTS

PARTS BREAKDOWN

SOLAR COLLECTOR LAYOUT

CONNECTING THE SOLAR COLLECTORS TOGETHER

MOUNTING COLLECTORS TO ROOF OR RACK

MOUNTING SCHEMATIC

MOUNTING THE SOLAR COLLECTORS ON A FLAT ROOF

10

ASSEMBLY OF ROW SPACER KITS

11

CONNECTING THE COLLECTORS TO THE FEED AND RETURN LINES

12

RUNNING THE FEED AND RETURN LINES TO GROUND LEVEL

13

HOW TO CONNECT THE SOLAR COLLECTORS TO EXISTING POOL FILTRATION SYSTEM

15

CONNECTING THE FEED AND RETURN LINES TO THE FILTRATION SYSTEM

16

Pressure Testing the System

17

Troubleshooting

18

REPAIR PROCEDURES

21

OPERATING AND CHECK OUT PROCEDURES

23

THATS ALL THERE IS TO IT!

24

SOLARHOT Collectors are manufactured utilizing cutting-edge technology and the most advanced production
techniques. A SOLARHOT System will provide years of worry-free performance as it captures safe, reliable heat from the
sun year after year.
This manual will give you a great deal of valuable information. Take time to read through it and view the Installation Video.
Both will guide you through the most efficient way to correctly install a SOLARHOT system. By following this step-bystep guide, your system will meet the installation standards recommended by the factory.
While this manual explains how to install SOLARHOT Panels properly in typical situations, it cannot address all the unique
or individual circumstances possible. If you have any installation questions, contact your SOLARHOT representative for
assistance. As the installing contractor, you are responsible for exercising good judgment when using SOLARHOT to
protect the long-term integrity of the collectors as well as the mounting surfaces.

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GETTING STARTED
Before you start your installation, here are a few important tips:
CAUTION-SAFETY COMES FIRST! There is no substitute for safety. Always exercise extreme caution, care and good
judgment when working on or around a roof or pool area.
Please take care to avoid hazards such as overhead electrical wires or loose shingles.
Be sure to secure ladders so they will not slip or fall.
Do not allow extension cords to lie in the pool or in standing water.
Wear shoes with proper tread to prevent slipping on the ladder or sloped roof areas.
Disconnect all power to the pool when installing an automatic control system.
Check with your local building department to determine permitting and code requirements in your area.
While this manual explains how to install SOLARHOT Solar Collectors properly in typical situations, it cannot possibly
address all the unique or individual circumstances possible. If you have any installation questions, contact your
SOLARHOT representative for assistance.
Before starting any work, determine the location of your system and prepare a schematic drawing of the installation area.
Include the location of the feed and return lines in this drawing. Roof areas often look bigger than they really are, so be
sure to measure the available area before making your schematic. Be sure that the layout of the collectors will allow the
collectors to drain when the pool pump shuts off.
Familiarize yourself with all of the SOLARHOT components and plumbing materials that you will need to complete the
installation.
Dont take shortcuts. Whenever possible, panels should be installed so they are accessible without being walked on.
Walking on the collectors should only take place when absolutely necessary.
Depending upon your specific job, you will need various plumbing items and materials. Be sure to use quality products
that will withstand direct sunlight year after year. Here are some recommendations:
PVC PIPE: Use PVC SCHEDULE 40 pipe. Do not use ABS or a lower standard substitute.
PVC FITTINGS: Use PVC SCHEDULE 40 pressure-rated fittings to match your PVC pipe.
DO NOT USE plumbers fittings or DWV fittings (Drain, Waste and Vent).
PVCV CLEANER AND CEMENT: It is important to both CLEAN and CEMENT each PVC joint. When gluing CPVC
fittings to PVC pipe, such as the {STR-PC} Pipe Connectors, it is necessary to use a good quality multi-purpose cement.
NOTE: While this manual explains how to install your SOLARHOT Solar System properly in typical situations, it cannot
address all the unique or individual circumstances possible. If you have any installation questions, contact your
SOLARHOT representative for assistance. As the installer, you are responsible for exercising good judgment when
installing SOLARHOT Systems to protect the long-term integrity of the collectors, as well as the mounting surfaces.

SOLARHOT Pool Installation Instructions

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THINGS TO REMEMBER
No two installations are exactly alike, but there are some general bits of technical information that you will find helpful in
the field.
ROOF ORIENTATION: Ideally, collectors should be located on a South-facing or flat roof, or on an elevated groundmounted rack facing South. The next best orientation is West, and finally East. A collector should NEVER be installed on
a North roof without a reverse rack.
COLLECTOR CONFIGURATIONS: There are many ways to configure a solar array. The most common or preferred is
in one continuous row. The recommended limit to the number of collectors that can be installed this way to achieve even
flow throughout the array is (10) STR-40s or (8) STR 50s.
The maximum guideline can be exceeded if there is high flow or substantial back pressure on the system which will force
adequate flow through every collector. When you have more than the maximum, though, you should either use the
Double Row layout or the Single Row Split Feed layout. The Double Row can also be used for smaller installations when
space is a problem.
If you have to split up an array due to a skylight or change in roof level or direction, the layout will be similar to Single Split
Row layout.
PUMP HORSEPOWER: The horsepower of your swimming pool filtration pump must be adequate to supply the solar
system with enough water to provide the recommended flow rate necessary for the collectors being installed. The
recommended rate for an STR-40 is 4 gallons per minutes and 5 gallons per minute on an STR-50.
Generally, a 1 horsepower pump is sufficient for a standard pool solar system unless there is an unusually long pipe run,
a high roof or a large number of collectors. If you are not sure what your pump flow rate is, consult your SOLARHOT
representative or pump manufacturer for the pumps flow characteristics.
PLUMBING: It is important that you use the proper size PVC pipe for the size of the solar array. Under sizing the pipe
will produce too much restriction to the water flow and unnecessarily reduce the flow rate to the collectors. Use the
following as a guide:
Flow Rate
0 to 45 GPM
46 to 80 GMP

Minimum Pipe Size

1-1/2
2

Plumbing runs should be as short as possible and the Hot Return pipe should have the shortest run to reduce the
potential heat loss in this pipe. Pipes should be supported with G-clamps at least every 5 feet o prevent sagging. The
G-clamp used on pipe runs across a roof should be 1/2 larger than the pipe diameter to allow for expansion and
contraction. C-clamps should be used on vertical or horizontal runs on the side of a building, and should be the same
size as the pipe diameter to prevent vibration.
AUTOMATIC DRAIN DOWN: The collectors and the PVC pipe should be installed so the water will drain out of them
when the pool pump shuts off. This is especially important in areas of the country where freezing conditions occur. (The
SOLARHOT Solar Pool Collectors are warranted against internal freezing when installed to allow for drain down.) If, as a
result of a unique roof design or adverse pool equipment location, it is not possible to achieve complete automatic drain
down, manual drain down valves should be installed in appropriate places in the plumbing or at the end of the bottom
(feed) header. [Instead of installing an {STR-ED} End Cap at the end of the header, you would place a {STR-VC} Vac Cap
along with a {BD-050} Boiler Drain. These valves should be opened when shutting down the system for the winter
months or when freezing conditions are possible. Your SOLARHOT representative can assist you with the parts
necessary for manual drain down installations.

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INSTALLATION KITS AND

COMPONENTS
The following is a description of the installation kits that are required for a complete SOLARHOT installation. The {STRSK} System Kit and {STR-CK} Collector Kits are always required while the {STR-RSK} Row Spacer Kit is only required for
certain installations. The {STR-PTK} Pressure Testing Kit is used during installation to test the system while the {STRRTK} Repair Tool Kit is used if you ever need to repair a collector.
STR-CK: COLLECTOR KIT
One of these kits is required for each collector. It contains two {STR-PPC} Plastic Panel Clamps and two {STR-MP}
Mounting Pads. Additional mounting pads will be necessary on roofs with a pitch of 10/12 or greater.
STR-SK: SYSTEM KIT
One of these kits is required for each row or bank of collectors. It contains the parts necessary to connect the collectors
to the feed and return lines.
STR-RSK: ROW SPACER KIT
One of these kits is required if you need to bypass a vent pipe, or obstacle larger than 6. It is also used to connect
collectors into one row that are on different roof levels or that are facing different directions. It contains the parts
necessary to connect the collectors to the PVC pipe between them.
STR-PTK: PRESSURE TESTING KIT
This kit gives you the components you need to pressure test the system once installation is complete.
STR-RTK: REPAIR TOOL KIT
In the event a collector is damaged, this kit contains everything needed to make a repair to a rise tube.

(See Table 4.1 for parts breakdown)

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PARTS BREAKDOWN
COMPONENTS
Part No.

Description

SR/CK

STR/SK

STR/RSK

STR-MP

Mounting Pad

STR-PPC

Panel Clamp with Gasket

STR-PC

STR/PTK

STR/RTK

Pipe Connector

STR-EC

End Cap

STR-JC

J-Clamp

STR-BV05

1/2 Ball Valve

STRP-PG

0-60 PSI Pressure Gauge

STR-PTT

Pressure Test T Assembly

STR-PIT

Pin Insert Tool

STR-C25

1/4 Chisel

OTHER INSTALLATION COMPONENTS

STR-VB.........Vacuum Breaker

STR-CV150.......PVC 1 1/2 Check Valve

STR-FL..........Flange

STR-CV200.......PVC 2 Check Valve

STR-GC.........G-Clamp

STR-BV2...........Two-Way Ball Valve

STR-LB200....1/4 x 2 Stainless Steel Lag Bolt

STR-JV3............Three-Way Jandy Valve

STR-TPC.......100 Tapcons 1/4 x 1-3/4 with Drill Bit

STR-GA.............Gasket for Panel Clamp

SOLARHOT Pool Installation Instructions

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SOLAR COLLECTOR LAYOUT

Shown below are the three most common Solar Collector installations.

SOLARHOT Pool Installation Instructions

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CONNECTING THE SOLAR

COLLECTORS TOGETHER
Later on in this installation manual you will be instructed to connect the collectors together using {STR-PPC} Plastic
Panel Clamps. When connecting collectors together, follow the directions outlined below:
1. Place two collectors next to each other. The spacer bars that hold the individual riser tubes together should be facing
down. Lay a {STR-PPC} Plastic Panel Clamp top, bottom, gasket and clip where the two headers meet. (Fig. 6.2 - A)
2. Clean the groove of both headers.
3. Spray the gasket with silicone and insert it into the groove of one of the headers. Make sure that the gasket is fully
seated into the header groove by pushing firmly with your thumb all the way around the gasket. (Fig. 6.2 - B)
4. Place the bottom half (see Fig. 6.3) of the {STR-PC} Plastic Panel Clamp under the collector header with the hook
portion of the panel clamp on the inside of the collectors. (Fig. 6.2 - C)
5. Seat both headers together by inserting the gasket into the opposite header groove and placing the ends of both
headers into the open space in the panel clamp bottom. (Fig. 6.2 - D)
6. Interlock the top half of the panel clamp with the hook on the bottom half. Swing top half over top of collector
headers. Squeeze the top and bottom portions of the panel clamp together using channel lock pliers and lock both
halves of the clamp together using the locking clip. (NOTE: Slide large end of locking clip over small end of Plastic Panel
Clamp assembly.) (Fig. 6.2 - E & F)
7. Use channel lock pliers to tighten the clip grip by squeezing it with reasonable force until it seats flush or even slightly
father so it cannot slide out of its position. (Fig. 6.2 - G)
8. Use this same procedure to connect both top and bottom headers of the collectors.
NOTE: On soft roof surfaces or lesser quality asphalt shingle, an EPDM or an aluminum pad underneath the panel clamp
may be necessary to eliminate possible wear.
FIG 6.2

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MOUNTING COLLECTORS TO ROOF OR RACK

The most important feature of the SOLARHOT installation method is its simplicity. The mounting pads flexibility allows
for the relatively simple installation of the SOLARHOT collectors on any roof or rack surface, regardless of pitch. To
properly install collectors utilizing mounting pads, follow these steps:
1. Prepare each collector by sliding the {STR-MP} Mounting Pads onto the mounting rail molded to the TOP HEADER.
Two Pads per collector are required for roofs with a slope or pitch less than 10/12 and should be located on the
mounting sections of the collector. Mounting Pads should never be installed on the bottom member since the panels
need to be free to expand and contract.

Number of Mounting Pads Required

Roof Pitch less than 10/12 (37.5*) - 2 Pads Required

Roof Pitch 10/12 or greater (37.5*) - 4 Pads Required

NOTE: Typically, each Mounting Pad should be centered on the mounting rail. However, the Pad can be slid from side to
side so that it can be centered on a roof truss or on the top of a barrel tile. You may even want to move the Mounting
Pad to a different mounting rail, but remember to always keep the Pads spaced out as evenly as possible.
2. Snap a chalk line across the roof where you want the top edge of the collector header to be. This chalk line should
slope upward towards where the return line will be located, 1 every 20 to allow for proper drainage. The return line
corner of the collectors should be the top corner closest to the pool pump so that once the water is heated, it will be
returned to the pool as quickly as possible. Be sure to allow 2 of clearance above this chalk line for the Mounting Pads.
3. Lay the first two collectors so that the top edge of the top header is located as the chalk line.
4. Connect the top headers of the collectors together using the {STR-PPC} Plastic Panel Clamp by following the
procedures described in the section of this manual on connecting solar collectors together.
5. After positioning the Mounting Pads in the proper location, secure the first collector to the roof. Apply ample silicone
to both lag bolts or appropriate roof fasteners and to the roof. Position Mounting Pad on the roof and lag to the roof.
The {STR-200} 1/4 x 2 lag bolt should be securely fastened, but no over tightened. In the case of tile roofs, tapcons
are commonly used to attach the Mounting Pads to the tile. Using tapcons avoids the need to penetrate the roof
membrane or substrate in cases where the roof tiles are properly anchored to the roof. On all types of roofs, be sure to
seal each penetration with the proper sealant.
6. Before securing the next collector to the roof, connect an additional collector to the row using the Plastic Panel
Clamp. This allows you to lift up the header of the adjacent collector when connecting the two collectors together.
7. Follow the procedures listed above until all collectors are connected to each other and anchored to the roof.
8. After all collectors are anchored to the roof, connect the bottom headers together with additional Plastic Panel
Clamps.
FIG. 7.1

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MOUNTING SCHEMATIC
NOTE: As the installing contractor, it is your job to evaluate any site-specific conditions that might create unwanted roof
wear. As an example, if you are installing the system on an inexpensive or soft asphalt shingle roof, youll want to put
some 4 x 4 pads underneath each panel clamp along the bottom headers to prevent roof wear. Some installers make
these pads from aluminum roof flashing or old mat systems, and attach them to the roof with silicone or an adhesive.
FIG. 7.2
SOLARHOT MOUNTING PAD
(Placed at panel rail)

NOTE: Install the J-Clamp 3 inside the panel clamp on the

corner opposite the feed line. The J-Clamp should also be 1/2
below the header to allow for expansion and contraction.
(See Figs. 7.2 and 7.3)
NOTE: SOLARHOT Mounting Pads are NOT used on the
bottom headers. They are used on the top header only.
FIG. 7.3

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MOUNTING THE SOLAR COLLECTORS

ON A FLAT ROOF
If you have chosen a flat roof area to mount the solar collectors, it is best not to penetrate the roof surface with a lag bolt.
FIBERGLASS-COATED, METAL OR SHINGLED FLAT ROOFS
If you have one of these these three types of roofs with at least 3 of slope down the panel length, you can use the
Mounting Pad installation method previously described. Use liquid adhesive instead of lag bolts to secure the Pad to the
roof.
BUILT-UP TAR AND GRAVEL ROOF AND ROOFS WITH NO SLOPE
If you have this type roof, use the following installation method.
FLAT ROOF METHOD USING PRESSURE TREATED 4X4s

FIG. 8.1
1. Remove any loose gravel from the roof where the top headers will be located.
2. Place a 43 section of pressure treated 4x4 on the flat roof at the location of each return header (see Fig. 8.1). Leave a
4 gap between each 43 section to
allow water to drain through. Secure the 4x4 to
the roof with a good quality liquid
adhesive.
3. Loosely attach {STR-MP} Mounting
stainless steel lag bolts.

Pad to the 4x4 using the {STR-200} 1/4 x 2

(Optional) If one of the plumbing lines runs next to the bottom header, you can loosely secure the bottom header to it
using black nylon electrical ties.
4. If you use a Row Spacer Kit with this assembly method, continue the 4x4 under the pipe between collectors to
prevent sagging. If it is a long run, clamp the pipe to the 4x4.
NOTE: The 4x4 can be cut at a bevel so as to allow the
collector to rest at a 10 to 15 degree angle. (See Fig. 8.2)
FIG. 8.2
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ASSEMBLY OF ROW SPACER KITS

One of the SOLARHOT advantages is that most roof vents can be circumvented without the use of a Row Spacer Kit.
However, if the obstruction is wider than 6 or if it is within 24 of the header, you will need to circumvent it by using
{STR-RSK} Row Spacer Kit.

FIG. 9.1

1. Connect the 4 {STR-PC} Pipe Connectors to the headers of the collectors to be connected with a {STR-PPC} Plastic
Panel Clamp using the same procedures outlines in the section on connecting solar collectors together on page X.
2. Cut two lengths of 1-1/2 PVC pipe long enough to cement the {STR-PC} Pipe Connectors on each collector to each
other. NOTE: When gluing CPVC fittings such as the Pipe Connector {STC-PC}, it is necessary to use a good quality
multi-purpose cement.
3. Cement the PVC pipe to the Pipe Connectors as shown in Fig. 9.1
4. If the distance between the collectors is over 4 feet, a 2 G-Clamp should be used on both pipes to prevent sagging.

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CONNECTING THE COLLECTORS

TO THE FEED AND RETURN LINES

1. The feed line will be connected to the low end of the bottom header as previously determined when the chalk line was
snapped. This should be the end farthest from the pool pump. The return line will be connected to the top header on
the opposite end of the array. This should be the end closest to the pool pump. (See Figures on page X.)
2. Attach the [STR-PC} Pipe Connector to the corners of the array where the feed and return lines will be using the {STRPPC} Panel Clamp as described in the section on conneccting solar collectors together on page X.
3. The {STR-PC} Pipe Connector allows 1-1/2 PVC Pipe or a 1-1/2 St. 90 to be glued directly into the socket, or a 2
PVC 90 to be glued on the outside. CPVC or multi-purpose glue should be used when attaching PVC fittings or pipe to
the Pipe Connectors to provide for a durable connection. A 90* PVC fitting and vertical pipe run of at least five feet
should always be attached to the return line Pipe Connector to allow for lateral expansion and contraction of the return
line pipe run.
4. Connect the feed and return pipes using good plumbing techniques.
5. Attache the {STR-EC} End Caps on the corners opposite the feed and return lines using the {STR-PPC} Panel Clamps
as described on page X.
FIG. 10.2

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RUNNING THE FEED AND RETURN LINES TO GROUND LEVEL

Discussed here is the standard, most straightforward way of running the PVC pipe from the feed and return lines to the
pool pump and filter or equipment pad. Some installations require a more creative approach due to unique roof designs
or equipment locations on the opposite side of a house. Whenever possible, however, the return line should have the
shortest run and all pipes should run slightly downhill to allow for automatic drain-down of the plumbing and solar array.
If the equipment pad is against the house, you may want to complete the necessary plumbing at the equipment pad
before completing this portion of the installation. This allows you to know exactly where the pipes should come down
from the roof. If you will be trenching from the equipment pad to the installation location this would not be necessary.
1. Cement the appropriate size PVC 90* elbow to the return line stub facing down toward the bottom header. (see Fig.
12.1 on page X).
NOTE: Whenever cementing, lay a rag on the roof or rack under the joint to avoid dripping cement on the mounting
surface. Also, it is a good idea to tape the cans of PVC cleaner and PVC cement together. They are less apt to tip over
and spill this way.
2. Determine where the feed and return pipes will go over the edge of the roof. If possible, this should be perpendicular
to the exact points where they will fasten into the existing system or into pipes coming from another location (see Fig.
13.1 on page X).
3. Measure the distance from the return elbow down to the spot that you want to go across the roof to the point
established above. Be sure to include the depth of the socket in the elbow in your measurement. Cut a piece of PVC
pipe to this length. Repeat this process for the feed line.
4. If you are not experienced at cutting and fitting pipe, it is a good idea to assemble all pipe and fittings before
cementing them, just in case you make an error. Clean the burrs off these cut pipe lengths and insert them into the
elbows.
5. Measure across the roof from these pipes to the points established in step 3. Cut and de-burr pipes to these lengths
and assemble corner with 90* elbows.
6. Continue this process around the edge of the roof and down to the existing plumbing, keeping pipes as short, straight
and tight to the building as possible.
7. Once you are satisfied with the plumbing arrangement, go back and cement all joints together.
8. Secure long pipe runs every 4 to 5 feet with G-Clamps or pipe straps one size large than the pipe diameter, using
Stainless Steel Lad Bolts and silicone caulk. Secure vertical pipe runs on the side of buildings with C-Clamps the same
size as the pipe diameter using screws and anchors as needed.
NOTE: Be sure to support all of the weight of the plumbing with G-Clamps or pipe straps. The Mounting Pads are not
designed to support the weight of the plumbing in addition to the weight of the collectors.
NOTE: All four corners of each row of collectors should be securely fastened to the roof. The feed and return corners
should already be secured with the G-Clamps or pipe straps on the plumbing lines and the top corner opposite the
return corner should already be secured with a Mounting Pad. Secure the bottom corner opposite the feed line with a JClamp by placing it halfway between the Panel Clamp and the mounting groove. The J-Clamp should also be 1/2
below the header to allow for expansion and contraction.

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FIG. 12.1
A: Feed line is attached to the
bottom header and an End Cap is
attached to the top header.
B: In this completed assembly, the
return line is attached to the top
header and an End Cap on
the bottom header.

C: The assembled return line

utilizes the STR-PC Pipe Connector,
STR-PPC Panel Clamp and a GClamp.

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SOLARHOT

HOW TO CONNECT THE SOLAR COLLECTORS

TO EXISTING POOL FILTRATION SYSTEM

FIG. 15.1

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CONNECTING THE FEED AND RETURN

LINES TO THE FILTRATION SYSTEM

Fig. 15.1 on page X shows how a typical SOLARHOT Solar Pool Heating System is plumbed into existing pool plumbing.
This drawing may not be just like every system you encounter. The feed and return plumbing on a solar system may be
reversed, or it may have a different type of filter, or it may have additional equipment such as a chlorinator, pool cleaner,
gas heater, etc. It may also have a long run of plumbing from the pool equipment to the solar collectors.
Whether the system is like this or not, Fig. 15.1 will help you understand the flow of water from the pool, through the
pump, filter, solar system and back to the pool. Study the diagram and become familiar with the valves need to connect
the solar collectors to existing plumbing.
Notice that the first Check Valve is plumbed in after the filter. This prevents the filter from being backwashed by the water
draining down the panels when the pump shuts off. The Three-Way Valve either diverts the water to the solar system or
directly back to the pool. This Three-Way Valve should be a non-positive valve. This enables the water in the solar
system to drain back to the pool when the pump shuts off. The Two-Way Valves on the solar feed and return lines allow
you to isolate (completely shut off) the solar system.
1. Study the plumbing after the filter and decide where you are going to install the Check Valve and the PVC tee fitting
(see Fig. 15.1). If you have auxiliary equipment, you may need to re-plumb a portion of your existing plumbing so this
equipment is located before or after the solar system as indicated in Fig. 15.1.
2. Cut the pipe after the filter where you have decided to locate the Check Valve and where your solar return pipe will
attached to your existing pool return line. If your pool plumbing is 1-1/2 and you are running 2 plumbing to your solar
system, you should be using 2 valves and piping for all of your new plumbing, so you will need (2) 2 x 1-1/2 reducer
bushings to adapt your new 2 fittings to the existing 1-1/2 pipe.
3. As discussed earlier in this manual, it is a good idea to assemble all pipe and fittings before cementing them, just in
case you make an error. Install a Check Valve on the pipe coming out of the filter. Be sure that the arrow showing flow
direction is pointed away from the filter.
4. The Three-Way Valve will be installed next. It may come right next to the Check Valve, or you may have to use some
pipe and fittings to locate it off of the main line. As stated earlier, use as few 90* elbows as possible.
5. Install the Two-Way Valve to the solar feed line and then connect the other side of the Two-Way Valve to one of the
ports on the Three-Way Valve.
6. Install the {STR-VB} Vacuum Breaker about 4 feet up the feed line using a PVC tee and reducer bushing. Face the tee
to the outside as shown in Fig. 15.1. Wrap the threads of the Vacuum Breaker with teflon tape and screw it into the 3/4
threaded reducer bushing.
7. Install the second Two-Way Valve to the solar return line.
8. Determine now where to locate the PVC tee fitting. The tee may be located right next to the Three-Way Valve or
elsewhere depending on your system. Connect the tee fitting first to the solar return line, then to the Three-Way valve,
and then to the pool return line.
9. Once you are satisfied with the plumbing arrangement, go back and cement together all joints that you have not
already cemented. Use good plumbing techniques and rags to protect the existing pool equipment.
NOTE: Use C-Clamps the same size as the outside diameter of your plumbing fittings to secure the pipe and fittings
tightly to the wall.

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Pressure Testing the System

Pressure testing the entire solar system provides for a trouble-free installation and takes only about fifteen minutes. Any
weak PVC glue joints, fittings or pipe, any improper Panel Clamp connections, will be evident while the system is put
under 40 to 50 pounds of pressure.
1. Allow ample time for all glue joints to dry completely. Use this time to wrap up things and to clean up the job site.
2. Wrap the threads of the {STR-PTT} Pressure Test T Assembly, {STR-VB05} 1/2 Ball Valve and {STR-PG} Pressure
Gauge with teflon tape. Replace temporarily the {STR-VB} Vacuum Breaker with the {STR-PTT} Pressure Test T
Assembly. Thread the {STR-BV05} 1/2 Ball Valve and Pressure Gauge into the Pressure Test T Assembly.
3. Attach a garden hose to the 1/2 Ball Valve. Make sure the 1/2 Ball Valve is in the off position.
4. Turn the solar system on to allow the pool pump to completely fill the solar system. (If the pool pump is not
operational, shut off the Ball Valve on the feed line and use the garden hose to fill the system.)
5. Once the solar system is completely full of wrater, turn off the pool pump or turn the Three-Way Valve to bypass the
solar system. Quickly turn off the Ball Valves on both the feed and return lines.
6. Turn on the city water to the garden hose and open the 1/2 Ball Valve on the Pressure Test T Assembly until the
Pressure Gauge reads 40 to 50 PSI and then turn off the 1/2 Ball Valve. Turn of city water.
7. With the system under pressure, check the whole system for any leaks. A drop in pressure on the Pressure Gauge
indicates a leak in the system.
8. If there are leaks, open the Ball Valve on the return line to relieve the pressure. Repair any leaks. Repeat the pressure
testing procedures as needed.
9. Return system to normal when through with pressure testing. Be sure to open both Ball Valves and replace the
Pressure Test T Assembly with the Vacuum Breaker.

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Troubleshooting
PROBLEM

CAUSE

SOLUTION

There are air bubbles in the pool

If the pump is making more noise,

Be sure the pump trap lid is on tight.

only when the solar is operating.

there may be air coming into the

pump through an air leak on the
suction side of the pump due to the

Check the O ring on the pump trap lid.

Clean, lubricate or replace as needed.

pump working harder to move the

If you have a suction-type pool cleaner,

water through the solar system.

remove it. If this improves the air bubbles,

only use it when not operating the solar.
If you have a clear lid on the pump and
can see air bubbles in the trap, using a
garden hose, run water over the lid and
each joint individually to see if the air
bubbles will clear up. If there is not a clear
lid, listen to pump noise for a smoother
operation. Repair any air leaks.

If the Vacuum Breaker is installed on

Be sure filter is clean. Backwash to

the roof, there is not enough

reduce pressure.

pressure in the solar system to keep

the vacuum relief valve closed and it
is allowing air to be drawn into the
water as it flows by the valve.

If an older system, check for debris or

scale in the mouth of the vacuum relief
valve and clean if necessary.
Use the STR-BV2 Ball Valve on the return
line to throttle the flow back to produce
more back pressure on the system.
Locate Vacuum Breaker on feed line as
shown in Fig. 15.1 and put an {STR-EC}
End Cap at the end of the top header
where the vacuum breaker was previously
located.

SOLARHOT Pool Installation Instructions

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PROBLEM

CAUSE

SOLUTION

Some of the solar panels are

There is not equal flow through all of

Be sure filter is clean. Backwash to

warm to the touch while others

the panels. Warm panels indicate

reduce pressure.

are cool to the touch.

low water flow.

The pump may not be providing enough

water to the solar system. Check water
flow using a flow meter. Increase pump
horsepower, if needed, to maintain
recommended flow.
If there is a suction-type cleaner in the
pool, remove it. If this eliminates the
problem, use it only when the solar
system is off.

If the system is a single row array:

If there is adequate flow, use the {STRBV2} Ball Valve on the return line to
throttle the flow back to produce more
back pressure on the system. This will
even out the flow through the panels.
If the array contains more panels than the
maximum recommended, change the
array to a double row or single row split
feed.

If the system is a double row or a

If there is adequate flow, install a {STR-

single row split feed array:

BV2} Ball Valve on the return side of the

set of panels that re the coolest to throttle
back the flow through these panels and
force more through the warmer panels.
If any section of the array contains more
panels than the maximum recommended,
make changes as needed to correct this.

SOLARHOT Pool Installation Instructions

SOLARHOT

PROBLEM

CAUSE

SOLUTION

There are leaks between the

PPC Latch is not tight enough to

Slide Latch farther across connection

headers at the Plastic Panel

seal the joint.

between top and bottom half of clamp.

PPC Gasket is not seated squarely in

Disassemble PPC and verify that Gasket is

grooves.

seated properly.

There is a pin-hole leak in one

If new installation, a manufacturing

Contact distributor for warranty repair

of the riser tubes.

defect.

information.

Riser tubes rubbing on roof surface.

Contact distributor for free repair kit and

Clamps.

adjust spacer bars to prevent future

damage.

Birds or squirrels have damaged

Contact distributor for free repair kit and

tubes while after seeds or nuts.

keep panels free of debris to prevent

future damage.

The water coming from the

The water is flowing too fast through

Waterflow through a single panel should

solar system is not as warm as

the panels.

be lass than 10 gallons per minute. Adjust

it should be.

the Three-Way Valve to bypass some of

the water.
Seasonal normal operation.

In the cooler months of the year, the

temperature rise through the panels may
only be 2*-3*. Use back of your hand to
feel the water temperature difference at
the pool return inlet.

The Three-Way or Ball Valve will

Internal parts need to be lubricated

If Valve has a grease fitting, turn it

not turn.

or replaced.

clockwise to inject grease into Valve, then

turn the diverter past the grease fitting to
spread the grease. If the grease fitting is
dry, fill it with silicone grease. If here is not
a fitting, disassemble Valve and lubricate
with silicone grease. Replace worn or
broken parts.

The automatic control system is

Various

not working.

SOLARHOT Pool Installation Instructions

Consult the manual for the automatic

system you have.

SOLARHOT

REPAIR PROCEDURES
The SOLARHOT Solar Collector is a very durable product, but there are a few steps you should take to protect its
longevity:
1. Try to avoid walking on the collectors. If you cannot avoid it, always wear soft-soled shoes.
2. Do not install SOLARHOT Collectors during temperatures lower than 35 degrees.
If any of the riser tubes in a SOLARHOT Collector should become damaged for any reason, it can be repaired using the
{STR-RTK} Repair Tool Kit and {STR-RP} Repair Plugs. The Repair Tool Kit consists of a 1/4 Repair Chisel, an Insert
Tool, and a PVC carrying case. Follow instructions for repair:
1. Utilizing the Repair Chisel, cut the damaged riser as close as possible to the header, carefully avoiding damaging
adjacent risers. The sloped side of the Chisel should face away from the header.

2. Spray the shaft of the Insert Tool and the rubber insert with silicone spray. Insert the Insert Tool into the rubber insert.
By holding the rubber insert with one hand and the Insert Tool with the other, gently stretch the rubber insert. As you do,
push the rubber insert all of the way into the headers opening. Stretching the rubber insert first allows for easier insertion
into the header.

SOLARHOT Pool Installation Instructions

SOLARHOT

3. Pull out the rubber Insert Tool. Using your fingers or a channel-lock pliers, push a poly-insert into the rubber insert as
far as you can.

4. Cut the riser tube to the desired length and slide it over the stub of the poly-insert for a straight, eye-pleasing fit.

5. REPEAT Steps 1-4 for the other end of the riser tube at the opposite header.

SOLARHOT Pool Installation Instructions

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OPERATING AND CHECK OUT PROCEDURES

Before you run water through the system:
Allow the cemented fittings adequate time to dry per manufacturers directions.
Verify that the Check Valves, Control Valves and Vacuum Breaker are installed properly.
Verify that ll Plastic Panel Clamp Clips are tight.
Pressure test the system as described on page X.
Verify that all Lag Bolts are secure and that adequate silicone was used to prevent any roof leaks.
Be sure all collector riser tubes are snapped into the spacer bars (except where they go around obstructions).
Be sure that collector riser tubes are NOT rubbing on the roof surface between spacer bars. If they are, adjust spacer
bars as needed to prevent this or a hole may develop in the riser tube.
Be certain that the system will automatically drain down when the pump is shut off or that enough manual drain valves
have been included.
Verify that all pipe runs are properly supported with G-Clamps.

TURNING THE SYSTEM ON

Turn the pool pump off.
Turn the Three-Way Valve so the closed indicator points toward the pool return side of the valve.
Be sure that the Two-Way Valve on the feed line is open.
Turn the pool pump on.
Set the pool pump timer, if used, so that the pump will run when sun is shining on the solar collectors. This is usually
between 10:00 a.m. and 4:00 p.m., but this will vary with geographic location and time of year.
When the solar system is running, you should notice:
A slightly higher pressure reading on the Pressure Gauge.
At midday, if the sun is out, warmer water should be coming into the pool. This water should be 3*-5* warmer than the
pool temperature. Use the back of your hand to better feel the difference in water temperature.
During the cooler months of the year it is essential that the pool surface be covered at night with a pool blanket to
maintain a comfortable water temperature. Low nighttime temperatures can lower the water temperature more than the
solar system can recover during the day.

TURNING THE SYSTEM OFF

Turn the pool pump off.
Turn the Three-Way Valve so the closedindicator points toward the solar feed side of the Valve.
If isolating the collectors, close the Two-Way Valve on the feed line after you are sure all the water has drained out of the
collectors and plumbing.
Turn the pool pump on to filter the pool as needed.

SOLARHOT Pool Installation Instructions

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THATS ALL THERE IS TO IT!

You have installed a SOLARHOT Solar Pool Heating System that has been tested and proven worldwide for quality and
reliability. If you run into any problems with your installation or have any future problems, call your SOLARHOT
representative.
BE SURE TO COMPLETE THE OWNERS REGISTRATION FORM OF THE WARRANTY AND MAIL IT BACK TO
SOLARHOT TO REGISTER YOUR INSTALLATION.
CONGRATULATIONS! If you have carefully followed the steps in this manual, you now have an efficient, professionallooking SOLARHOT Solar Pool Heating System.

SOLARHOT Pool Installation Instructions