Residential Installation Manual

Swimming Pool Solar Heating System

Heliocol 2011
Revised 09/11
 Disclaimer:
Before attempting installation, read these instructions carefully. This manual contains easy to follow step-by-
step procedures to properly install a Heliocol system. A little time spent understanding the system and its parts
will assure a successful, trouble-free installation. If you have any product or installation questions regarding this
system, contact your Heliocol Representative. When working on or around your roof or pool, please take care
to avoid hazards such as electrical wires and loose shingles or tiles. CAUTION! Safety comes first!
It is important to recognize that this manual outlines the recommended installation methods and practices as
prescribed by the factory. It is designed to aid a seasoned contractor or novice do-it-yourself individual while
providing optimum protection for the products. It is not designed to override any local codes or ordinances.
Also, these are the minimal requirements; additional hardware or protection may be required in hazardous
environments or in areas subject to extremes of weather or microburst climate events. In those areas, the lo-
cal expertise of the contractor may be relied upon in coordination with factory approval for special installation
considerations.

1
Introduction
Welcome to the Heliocol Family
Heliocol Solar Collectors are manufactured utilizing state-of-the-art solar technology and the
most advanced production techniques. Heliocol collectors are sleek and simple, yet the pat-
ented over-molded design makes Heliocol durable enough to last a lifetime. However, a pro-
fessional installation is very important to the overall success of a system. Installed properly, a
Heliocol System will be virtually maintenance free as it captures free, abundant and reliable
heat from the sun year after year. Whether you are a seasoned contractor or a homeowner
installing your own system, this manual will give you a great deal of valuable information.
Take time to read through this manual. It will guide you through the most efficient way to cor-
rectly install a Heliocol Solar System. By following this step by step guide, your system will
meet the installation standards recommended by the factory (see disclaimer on page 1). In
addition, because we’ve included techniques and tips gathered from experienced Heliocol
contractors throughout the country, using this installation guide will save you time and effort.

Table of Contents
Introduction 2
Getting Started 3
Collectors and Installation Kits 5
Parts List 6
Solar Collector Layout and Hydraulics 7
Connecting the Solar 12
Mounting the Solar Collectors on a Flat Roof 13
Assembly of Row Spacer Kits 14
Connecting the Solar Collectors to the Feed and Return Lines 15
Running the Feed and Return Lines from the Roof to Ground Level 16
How to Connect the Solar Collectors to the Existing Pool Filtration System 18
Pressure Testing the Heliocol Solar System 20
Operating and Check-Out Procedures 21
Installation Troubleshooting 22
Specifications 24

2
 Getting Started
Before you begin your installation, here are a few important tips:
1. Caution – Safety Comes First ponents and plumbing materials that you will need
to complete the installation. Here is a list of materials
There is no substitute for safety. Always exercise ex-
most commonly used:
treme caution, care and good judgments when working
on or around a roof or pool area. Pipe
• Please take care to avoid hazards such as over- Use pressure rated Schedule 40 PVC pipe. You may
head electrical wires or loose shingles or roof prefer to use black, as opposed to white, PVC pipe on
tiles. the roof for aesthetic reasons. But because black PVC
can be difficult to find, some installers have inquired
• Be sure to secure ladders so they will not slip
about the use of black ABS pipe instead. DO NOT USE
or fall.
ABS PIPE. ABS pipe does not have the UV inhibitors
• Do not allow extension cords to lie in the pool that PVC pipe has, causing ABS pipe to become brittle
or in standing water. and to crack after several years of exposure.
• Wear shoes with proper tread to prevent slip- Pipe Fittings
ping on the ladder or sloped roof areas.
Use PVC Schedule 40 pressure-rated fittings to match
• Disconnect all power to the pool equipment your PVC pipe. Be sure NOT TO USE “plumbers” fit-
when installing an automatic control system. tings or DWV fittings (drain, waste and vent). Because
black PVC fittings are difficult to find, some installers
2. Always consult with the proper authorities or check
use spray paint to paint them black. Should you do so,
with your local building department for the permit re-
it is necessary to use a high-quality paint, preferably
quirements and codes applicable before you start your
with UV inhibitors. Do not use inexpensive “discount
job. Some installers prefer to use white pipe and fittings
store” brands as these will fade and peel very quickly.
on the roof, then paint the pipe and fittings a color that
closely matches the roof. The paint should be outdoor PVC Cleaner and Cement
rated and UV resistant. Painted pipes and fittings will
It is important to both CLEAN and CEMENT each PVC
require additional maintenance. Most building depart-
joint. Use a quality, brand-name product and refer to
ments require permits for installing solar pool heaters, a
the product’s label for specific directions for use. Before
practice strongly supported by Heliocol.
applying cement, be sure to clean each fitting and pipe
3. Before starting any work, determine the location of end with the PVC Cleaner or “primer.” Soon after clean-
your system and prepare a schematic drawing of the ing each part, apply ample cement first to the fitting
installation area. Include the location of the feed and and then to the pipe end. Insert the pipe end into the
return lines in this drawing. Roof areas often times look fitting with a slight twisting motion until it seats to evenly
bigger than they really are, so be sure to measure the distribute the glue. Hold it in this position for 5 to 10
available area before making your schematic. Be sure seconds to allow the joint to set up. Finally, wipe excess
the planned placement of the collectors will allow the cement off of the joint and pipe. When gluing CPVC
collectors to drain when the pool pump shuts off. fittings to PVC pipe, such as the Heliocol 117 Pipe
Connector, it is necessary to use a good quality CPVC
4. To ensure a trouble-free system, don’t take short-
all-purpose cement.
cuts. Whenever possible, collectors should be installed
so that they are accessible without being walked on. Note: Cold weather slows the set-up process for PVC
Walking on the collectors should only take place when glue. If installing in colder climates, refer to the PVC
absolutely necessary.(Never walk on collectors when glue manufacturer’s charts for curing times.
they are wet as they present a significant slip hazard)
Miscellaneous
5. Familiarize yourself with all of the Heliocol com-
Depending upon your specific job, you will need other

3
plumbing items and materials such as: PVC valves, stain-
less steel lag bolts, polyurethane caulk, silicone spray,
pipe straps, black electrical wire ties, electrical wire nuts,
18ga-22ga sensor wire, 12ga-14ga electrical wire with
ground, Teflon tape, concrete anchors and screws, elec-
trical conduit, etc. Be sure to us quality products that will
withstand direct sunlight year after year.

Tools
Planning ahead and having the proper tools and materi-
als on the job will make your installation much easier.
Typical tools and materials that are useful to have are:

• Flat head and Phillips head screwdrivers • Lanyards

• Power drill with bits, 5/16’ and 7/16” • Ropes
sockets and drivers
• Hard hats (where required)
• Pipe cutter or hacksaw
• Garden hose
• Hammer
• Tape measure
• Level
• Channel lock pliers
• Marking pen
• Caulking gun
• Silicone Lubricant
• Ladder
• Safety belts
• Chalk line

Note: While this manual explains how to install Heliocol Solar Collectors properly in typi-
cal situations, it cannot address all the unique or individual circumstances possible. If
you have any installation questions, contact your Heliocol Representative for assistance.
As the installing contractor, you are responsible for exercising good judgment when in-
stalling Heliocol Systems to protect the long term integrity of the collectors as well as the
mounting surfaces.

4
 Collectors and Installation Kits
Heliocol Components RSK: Row Spacer Kit
There are three Heliocol components to each system— One of these kits is required if you need to bypass a
collectors, collector kits and row kits. For each Heliocol vent pipe or obstacle larger than six inches. It is also
Collector that you install, you will need a collector kit. used to connect collectors that are on different roof lev-
For each row (bank) of collectors that you install, you els or that are facing different directions into one row. It
will need a row kit. To go around vents or pipes larger contains the parts necessary to connect the collectors
than six inches (chimneys, skylights or changes in roof to the PVC pipe between them.
elevations), you will need a row spacer kit. Refer to the
kit contents table below for more information regarding
these kits. Other Kits
PK: Collector Kit PTK: Pressure Testing Kit

One of these kits is required for each collector. It This kit gives you the components you need to pres-
contains the parts necessary to connect the collectors sure test the system once the installation is complete.
together and mount them on the installation surface. RTK: Repair Tool Kit
RK: Row Kit In the event a collector is damaged, this kit contains
One of these kits is required for each row (bank) of col- everything needed to make a repair to a riser tube.
lectors. It contains the parts necessary to connect the
collectors to the feed and return lines or collector header.

Kit Contents
PK RK RSK PTK RTK
106A
110 Short GATOR CLAMP
110 Long GATOR CLAMP
113

117
140
141
142 Y
130
133

Other Installation Components Referred to in this Manual

110BTS 126 1/4” X 2” STAINLESS STEEL LAG BOLT
111 127
116 1/4” x 4” STAINLESS STEEL LAG BOLT 1790
120 3344
121A 5210
124 “G” PIPE CLAMP
125 1/4” X 1-1/2” STAINLESS STEEL LAG BOLT

5
Parts List
113L 113T
(Latch) (Top)

113G
(Gasket)
106A
117 113B
End Cap
Pipe Connector (Bottom)

113
Collector Clamp

100 Short
HC-0110 SHORT 100 Long
HC-0110 LONG
Gator
ALLIGATOR Clamp
CLAMP Gator Clamp
ALLIGATOR CLAMP

142 140 141

Pressure Test “T” Assembly 1/2” Ball Valve Pressure Gauge

133 130
1/4” Chisel Pin Insert Tool

6
 Solar Collector Layout and Hydraulics
Shown Below are the Most Common Solar Collector Installations

Fig. 1.1 - Single Row

Fig. 1.2 - Double Row

Fig. 1.3 - Single Row Spit Feed

Fig. 1.4 - Series Feed

Note: No more than two (2) arrays are allowed in series feed
and no more than eight (8) collectors are allowed in each array.
7
Roof Orientation Collector Configurations
(Northern Hemisphere) There are many ways to configure a solar array. The most
common and preferred is in one continuous row as in Fig.
Ideally, collectors should be located on a south-facing or
1.1. There are, however, recommended limits to the number
flat roof, or on an elevated, ground-mounted rack facing
of collectors that can be installed in this way to achieve
south. The next best orientation is west, then east. Fi-
even flow throughout the array. The maximums are:
nally, if arrangements are maid for proper draining, then
Model # Maximum Per Row
low-pitched or flat. A collector should never be installed
30 12
on a north roof without a reverse rack in the northern
40 10
hemisphere. 50 8
52 7
There are conditions which may exist, especially on exist-
Choosing the Right Size Collector ing pools, where the pump used for filtration is inadequate
The roof space available to you will determine which to generate enough flow (GPM). Because of the unique
model collector to use. Since Heliocol manufactures col- design of the Heliocol collector, arrays of collectors can be
lectors in ten different sizes, you have great flexibility in plumbed in series (Fig. 1.4). Specific rules apply for series
what you can design. The ten collector sizes are: feeding regarding the number of collectors in arrays and
drain-down considerations. Please contact a factory repre-
Model # Nominal Size sentative for assistance with design criteria.
8 1’ x 8’
9.5 1’ x 9.5’
10.5
12.5
1’ x 10.5’
1’ x 12.5’
Pump Horsepower
*15.5 1’ x 15.5’ The horsepower of your swimming pool filtration pump
30 4’ x 8’ must be adequate to supply the solar system with
38 4’ x 9.5’ enough water to provide the recommended flow rate
40 4’ x 10.5’ necessary for the collectors being installed. These recom-
50 4’ x 12.5’ mended rates in gallons per minute (GPM) are:
*62 4’ x 15.5’
*Special Order Model # Minimum Flow
10.5 1 GPM
12.5 1 GPM
Whenever possible, the 50 should be used. This will: 30 3 GPM
40 4 GPM
50 5 GPM
• Reduce your total collector cost 62 6 GPM
• Reduce labor and installation material cost
For example; if you are installing ten 40 collectors, your
• Reduce the length of the solar array
pump must be able to deliver 40 GPM to the solar array.
• Reduce the number of roof penetrations These flow rates may be exceeded by as much as 100%
• Produce a more attractive installation without any detrimental impact on the performance of the
system. The existing pool recirculation pump is typically
adequate for recirculating the water through the solar
However, unique roof designs may require a combina- system. Generally, a 1 horsepower pump is sufficient for
tion of different size collectors to best cover the roof a standard pool solar system unless there is an unusually
area. 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 Heliocol representative or pump manufacturer for
the pump’s flow characteristics.
8
 Plumbing ent than the examples. Your Heliocol representative can
also assist with this and explain the use of “balancing
It is important that you use the proper size PVC pipe valves” on larger systems.
for the size of the solar array. Using a pipe that is too
small will produce too much restriction to the water flow If you are installing the solar collectors on a flat roof or
and unnecessarily reduce the flow rate to the collectors. flat ground rack, the top (return) header of the collec-
Use the following as a guide: tor should be a least 3” higher than the bottom (feed)
header to assure equal flow through all of the tubes of
Flow Rate Recommended Pipe Size all of the collectors. (See pg. 13) To achieve even distri-
0 to 45 GPM 1 ½” bution of water throughout the row of collectors, proper
46 to 80 GPM 2”
flow rates and a little back pressure should be present.

For larger flow rates, consult your Heliocol representa-

tive for the proper pipe size or alternative series plumb- Automatic Drain Down
ing techniques which will reduce the necessary flow The collectors and the PVC pipe should be installed
rates on larger systems. so the water will drain out of them when the pool pump
Plumbing runs should be as short as possible and the shuts off. This is especially important in areas of the
“hot return” pipe should have the shortest run to reduce country where freezing conditions occur. (The Heliocol
potential heat loss in this pipe. Pipes should be sup- solar pool collectors are warranted against internal
ported with pipe clamps or “G” pipe clamps at least freezing when installed to allow for drain down.) To
every four feet to prevent sagging. (Check the plumbing allow for the water to drain a vacuum breaker, 121 is
code in the local jurisdiction.) The pipe clamp used on installed on the solar feed line above the non-positive
pipe returns across a roof should be ½’ larger than the 3-way valve as shown on page 18, Fig. 15. (Non-positive
pipe diameter to allow for expansion and contraction. means that the valve allows for water to drain back
The pipe clamp used on vertical roof piping or piping through the valve even when in the off position. If you
running up the sides of the building should be the same have a 3-way valve that is not non-positive, you can
size as the pipe diameter to prevent vibration and to make it so by drilling a 1/8” hole in the diverter.) If, as
assure a professional-looking installation. a result of a unique roof design or adverse pool equip-
ment location, it is not possible to achieve complete
Since 90 degree elbow fittings produce a high restric- automatic drain down, manual drain down valves should
tion to flow, you will want to use a few as possible. Keep be installed in appropriate places in the plumbing or at
this in mind when planning your plumbing runs. Their the end of the bottom (feed) header. Instead of installing
use cannot be avoided, but with careful forethought, an end cap 106A at the end of the header, you would
you will use the least number possible. Occasionally, place a pipe connector 117, a 1 ½” slip x 1/2” threaded
the use of two 45 degree fittings will eliminate a 90, but PVC reducer bushing along with a ½” boiler drain 140.
it is not necessary to always use them as this will run These valves should be opened when shutting down the
up the expense of your materials. system for the winter months or when freezing condi-
tions are possible. On flat roof installations, it might be
necessary to open the collector connections at the end
Balanced Flow of the swimming season and manually lift the collectors
When you have to split a solar system (Fig. 4.2 or Fig. to evacuate all the fluid from the system. Your Heliocol
4.3, pg. 7) it is critical that the shown plumbing runs be representative can assist you with the parts necessary
followed to assure equal water flow through both rows for manual drain down installations.
of collectors. Since water will follow the path of least re-
sistance, if one plumbing run is shorter than the other,
more water will flow through it than through longer one.
Keep this in mind if you design a collector layout differ-

9
 Mounting the Solar Collectors
Using Gator Clamps
The beauty of the Gator Clamp installation is its simplic-
ity. It can be used on just about any type of roof or rack
installation.
110 Short
HC-110 Gator
Short Clamp
Alligator Clamp
Collector Header (Top)
113T Collector Clamp Top
113L Latch

113G Gasket

Fig. 2 113B Collector

Clamp Bottom
110 Long
HC-110 Gator
Long Clamp
Alligator Clamp

For rack systems, asphalt shingle roofs or tile roofs, fol- be positioned so that it is centered on the top ridge of a
low these simple steps: tile, still as close to 24” centers as possible.
1. Snap a chalk line across the roof or rack where you 4. Since normal horizontal expansion and contraction of
want the top edge of the collectors to be located. The an array of collectors takes place every day as collec-
collectors should slope slightly down toward the feed tors heat up and cool down, it is preferable to lock the
end of the array for proper drainage. center of each array in place so that the expansion and
contraction takes place evenly to the left and right of this
2. Locate the center of the first truss/rafter you plan to
center point. The center collector of an array may be
start from and drill a pilot hole where the first lag screw
locked in place by locating the clamps on that collector
will penetrate the roof. After verifying the pilot hole
adjacent to the left and right of one of the header ribs.
properly penetrated the structural wood truss or rafter,
(Fig. 4, pg. 11) these clamps should be attached using
measure and mark off the center-to-center truss dimen-
two lag bolts as opposed to one. Do not use this proce-
sions for the rest of the trusses being used. This as-
dure more than once on any array of collectors.
sumes trusses are located on 24” centers. Position the
first clamp on the chalk line six (6) inches in from the 5. Apply ample sealant to the bottom of the clamp over
top corner of the first collector. The first collector will be the hole or holes where the anchor bolt will attach (be
the one that is connected to the feed line at the bottom generous with sealant). (Fig. 5-A, pg. 11) Position the
header. bottom portion of the clamp perpendicular to the chalk
line with the lower hole being placed right on the chalk
3. Subsequent clamps should be spaced out evenly
line. Lag the clamp to the roof through the lower hole
along the chalk line every 24”. Each clamp can be
using a 1/4” x 4” S.S. lag bolt. (Fig. 5-B, pg. 11) For bar-
located anywhere along the top header to match up to
rel tile roofs, place four (4) 110BTS barrel tile spacers
the spacing of the roof rafters as long as there is a 2”
underneath each clamp by inserting the four feet of the
space between the edge of the clamp and the ribs (See
barrel tile spacer into the four corners of the bottom of
“ribs” in Fig. 14, pg. 17) on the collector header that exist
the clamp. (Fig. 6, pg. 11)
every one foot. This allows for horizontal expansion and
contraction. For barrel tile roofs, each clamp needs to 6. The bottom of the clamp is designed to grip the roof’s
10
 surface to avoid rotation back and forth; however, if the 9. Install two (2) SS screws (#6 x ¾) to secure clamp
roof surface is particularly hard or slick you can use an top to clamp bottom assembly.
additional lag bolt in either the top or center hole.
10. Attach the bottom headers of the collectors with 113
7. To ensure proper spacing, hang the top headers of collector clamps.
collectors in the bottom portion of the clamps attached
11. Locate and mount the clamps (2 each) along the
to the roof as you go. Once again, be sure clamps are
bottom header, aligned with the upper header clamps.
at least 2” away from each ridge along the header. (Fig.
The bottom clamp should be installed allowing a large
5-D)
gap on the top, allowing for contraction.
8. Once all clamps are properly lagged to the rack or
12. Attach feed and return lines following Heliocol’s
roof surface, and all the collectors are hung in place,
published guidelines.
connect the top headers of each collector using 113
collector clamps. Snap the top portion of each clamp 13. The corners where the feed and return are located
over the collector header onto the bottom portion of should be fastened down by pipe straps that are also
each clamp by pushing down firmly. (Fig. 5-C) supporting the pipe.
Note: Additional clamps are required for sur-
faces with a pitch of 10/12 or greater.
Pipe Strap
Note: To allow for vertical expansion and con-
traction, any clamps installed on the bottom
header must be positioned so that the header
is in the middle of the cradle. (Fig. 7)

Pipe Strap Fig. 3 Fig. 4

Fig. 5-A Fig. 5-B Fig. 5-C Fig. 5-D

110BTS
Gator Feet

11 110BTS
Gator Feet
Fig. 6 Fig. 7
Connecting the Solar Collectors Together
In subsequent pages of this installation manual, you will
be instructed to connect Heliocol collectors together by
using the 113, plastic collector clamps. It is helpful to

t
familiarize yourself with this procedure ahead of time. To
assure a proper connection, follow these steps:
1. Lay two collectors next to one another with riser tube
spacer bars on the bottom. Lay an 113 plastic collector
clamp top, bottom, gasket and latch at both ends where
the headers meet. (Fig. 8-A) Fig. 8-A Fig. 8-B
2. Clean the groove of both headers.
3. Spray the gasket with a silicone spray only. (An easy
way to do this is to put all of the gaskets in one plastic
bag. Spray silicone into the plastic bag to lubricate all of
the gaskets at once.)
4. Insert gasket into the groove of one of the headers.
(Fig. 8-B) (Half in, half out.)
5. Place the bottom half of the plastic collector clamp
Fig. 8-C Fig. 8-D
(113) under the header end with the larger flat portion
facing the roof.
6. 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 plastic collector
clamp bottom. (Fig. 8-C)
7. Interlock the top half of the plastic collector clamp
with the tab on the bottom half. Swing top half closed
over top of headers. Caution: Be sure to align top and
bottom so riser tubes pass through notch space in Fig. 8-E Fig. 8-F
interlocking end of collector clamp. (Fig. 8-G) Lock both
halves of the clamp together using the latch. (Note:
Slide large end of latch over small end of plastic collec-
tor clamp assembly. (Fig. 8-D and Fig. 8-E)
8. Use channel lock pliers to tighten the latch grip by
squeezing it with reasonable force until it seats flush or
even slightly farther so it cannot slide out of its position.
t Notch Space
(Fig. 8-F)
t

9. Repeat the procedure to connect the bottom headers

of the collectors. Riser
Tube

Note: Now using four (4) Gator clamps,

neither the top or bottom header touches
Fig. 8-G
the roof.

12
 Mounting the Solar Collectors on a Flat Roof
Multi-Ply Flat Roof

Single-Ply Flat Roof

Asphalt Built Up Flat Roof

13
Assembly of Row Spacer Kits
When you need to install collectors over an obstruction
larger than six (6) inches wide, or if the obstruction is
less than one foot from a collector header, you’ll need a
row spacer kit to circumvent the obstruction.

Fig. 9

RSK Warning: This should not be done between

the header and the first spacer bar as it will
Connect the four (4) 117 pipe connectors to the head-
possibly pull the riser tube out of the head-
ers of the collectors to be connected with a 113 plastic
collector clamp using the same procedures outlined in
er. The Heliocol warranty does not cover
the section on connecting solar collectors together on leaks occurring from this type of incorrect
page 12. installation. A row spacer kit could be used
for this situation.
Cut two lengths of 1-1/2” PVC pipe long enough to ce-
ment the 117 pipe connectors on each collector to each Flexible riser tubes are snapped out of the spacer bars
other. to go around small obstructions. The spacer bar may
need to be cut out of the way if it falls in the obstruc-
Cement the PVC pipe to the pipe connectors as shown tion’s path.(Fig. 10)
in Fig. 9.
If the distance between the collectors is over 4 inches,
a 2-inch pipe clamp should be used on both pipes to
prevent sagging.

Note: When gluing the 117 CPVC pipe con-

nectors, it is necessary to use good quality,
multi-purpose cement. The spacer bar may
need to be cut out of the way if it falls in
the obstruction’s path.
Fig. 10

14
 Connecting the Solar Collectors
to the Feed and Return Lines

1. The feed line will be connected to the low end of the degree to be glued on the outside. All-purpose cement
bottom header which should be the corner farthest from should be used when attaching PVC fittings or pipe to
the pool pump. The return line will be connected to the the pipe connectors to provide for a durable connec-
top header on the opposite end of the array. This gives tion. A 90 degree PVC fitting and vertical pipe run of at
the heated pool water the shortest route back to the least five feet should always be attached to the return
pool. line pipe connector to allow for lateral expansion and
contraction of the return line pipe run.
2. The 106A end caps will be located on the corners of
the solar array opposite of the corners where the feed 5. Connect the feed and return pipes using good
line and return lines will be. Attach the 106A end caps plumbing techniques.
using the 113 plastic collector clamp as described on
page 12. (See Fig. 11)
3. Attach the 117 pipe connectors to the corners of the
Note: Be sure to align the top and bottom
array where the feed and return lines will be, using the of the clamp so that the riser tubes can
113 plastic collector clamp. (See Fig. 12) pass through the notch space in the inter-
locking end of the collector clamp. A clamp
4. The 117 pipe connector allows a 1 ½” PVC street
that is improperly aligned can cause dam-
90 to be glued directly into the socket, or a 2” PVC 90
age to the riser tubes (See Fig. 13).

t Notch Space

Fig. 11 Fig. 12 Fig. 13

15
Running the Feed and Return Lines
from the Roof to Ground Level
Discussed here is the standard, most straightforward the elbows.
way of running the PVC pipe from the feed and return
5. Measure across the roof from these pipes to the
lines to the equipment pad. Some installations require
points established in step 3. Cut and de-burr pipes to
a more creative approach due to unique roof designs
these lengths and assemble corner with 90 degree
or equipment pad locations. Whenever possible, how-
elbows.
ever, the return line should have the shortest run and all
pipes should run slightly “downhill” to allow for auto- 6. Continue this process around the edge of the roof
matic drain-down of the plumbing and solar array. As and down to the existing plumbing, using a level to keep
discussed earlier, if this is not possible, manual drain the pipes looking plumb and keeping pipes as short,
valves should be installed as needed. straight and tight to the building as possible.

If your equipment pad is against your house, you may 7. Once you are satisfied with the plumbing arrange-
want to complete the necessary plumbing at the equip- ment, go back and cement the joints together using the
ment pad before completing this portion of the instal- good plumbing techniques explained in the “Getting
lation. This allows you to know exactly where the pipes Started” section.
should come down from the roof. If you will be trenching 8. Secure long pipe runs with pipe clamps or “G” pipe
from the equipment pad to the installation location, this clamps one size larger than the pipe diameter using
is not necessary. (116) #14 S.S. hex head screws and polyurethane caulk.
1. Cement the appropriate size PVC 90 degree elbow Secure vertical pipe runs on the side of buildings with
to the return line stub facing down toward the bottom pipe clamps the same size as the pipe diameter using
header. Repeat the process for the feed line header screws and anchors as needed.
stub and face the elbow down away from the array (see
Fig. 14, page 17)
Note: All four corners of each row of collec-
Note: Whenever cementing, lay a rag on the
tors should be surely fastened to the roof.
roof or rack under the joint to avoid dripping
The corners should already be secured
cement on the mounting surface. Also, it is
with the “G” pipe clamps or pipe straps on
a good idea to tape the cans of PVC cleaner
the plumbing lines connected to the feed
and PVC cement together. They are less
and return lines. The top corner opposite
likely to tip over and spill this way.
the return corner should already be se-
2. Determine where the feed and return pipes will go cured by the collector mounting hardware.
over the edge of the roof. If possible, this should be per-
pendicular to the exact points where they will fasten into
the existing system or into pipes coming from another Note: Be sure to support all of the weight
location. (See Fig. 15, pg. 18) of the plumbing with “G” pipe clamps or
3. Measure the distance from the return elbow down to pipe straps. The mounting hardware is
the spot that you want to go, across the roof, to the point not designed to support the weight of the
established above. Be sure to include the depth of the plumbing in addition to the weight of the
socket in the elbow in your measurement. Cut a piece of collectors.
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
16
 End Cap u

t Return Line

Rib p
End Cap p
Feed Line q

Fig. 14

17
How to Connect the Solar Collectors
to The Existing Pool Filtration System
(121)

WIRE TO ROOF SENSOR

(PTK)

(5210) (5210)

Manual
(3344)
Wire to Optional
Motorized Actuator
(1790)
Optional Motorized Actuator

Fig. 15
18
 How to Connect the Solar Collectors
to The Existing Pool Filtration System
Fig. 15 on page 18 shows how a typical Heliocol solar 3. As discussed earlier in this manual, it is a good idea
pool heating system is plumbed into existing pool to assemble all pipe and fittings before cementing them
plumbing. This drawing may not be just like every sys- just in case you make an error. Install a union check
tem you encounter. The feed and return plumbing on a valve on the pipe coming out of the filter. Be sure that
solar system may be reversed, or it may have a different the arrow showing flow direction is pointed away from
type of filter, or it may have additional equipment such the filter.
as a chlorinator, pool cleaner, gas heater, etc. It may
4. The three-way valve will be installed next. It may
also have a long run of plumbing from the pool equip-
come right next to the check valve, or you may have to
ment to the solar collectors.
use some pipe and fittings to locate it off of the main
Whether the system is like this or not, Fig. 15 will help line. As stated earlier, use as few 90 degree elbows as
you understand the flow of water from the pool, through possible.
the pump, filter, solar system and back to the pool.
5. Install the ball valve to the solar feed coming out of
Study the diagram and become familiar with the valves
the three-way valve.
needed to connect the solar collectors to the existing
plumbing. 6. Install the 121A vacuum breaker about 4 feet verti-
cally above the filter, up the feed line, using a PVC tee
Notice that the union check valve is plumbed in after
and red reducer bushing. Face the tee to the outside
the filter. This prevents the filter from being backwashed
as shown in Fig. 12.1. Wrap the threads of the vacuum
by the water draining down from the collectors when
breaker with Teflon tape and screw it into the ¾”
the pump shuts off. The three-way valve either diverts
threaded reducer bushing.
the water to the solar system or directly back to the
pool. This three-way valve should be a non-positive 7. Install the second ball valve or check valve to the
valve. This enables the water in the solar system to solar return line.
drain back to the pool when the pump shuts off. (If your 8. Now determine where to locate the PVC tee fitting.
three-way valve is not non-positive you can make it so The tee may be located right next to the three-way
by drilling a 1/8” hole in the diverter.) The ball valves valve, or elsewhere, depending on your system. Con-
on the solar feed and return lines allow you to isolate nect the tee fitting first to the solar return line, then to
(completely shut off) the solar system. A check valve the three-way valve, and then to the pool return line.
can be substituted for the ball valve on the return pipe
side if desired. 9. Once you are satisfied with the plumbing arrange-
ment, go back and cement together all joints that you
1. Study the plumbing after the filter and decide where have not already cemented. Use good plumbing tech-
you are going to install the union check valve and niques and use caution not to drip glue or cleaner on
the PVC tee fitting (See Fig. 15). If you have auxiliary existing pool equipment, or inside any valves.
equipment, you may need to re-plumb a portion of your
existing plumbing so this equipment is located after the Note: Use pipe-clamps the same size as
solar system as indicated in Fig. 15. the outside diameter of your plumbing fit-
2. Cut the pipe after the filter where you have decided tings to secure the pipe and fittings tightly
to locate the union check valve and where your solar to the wall.
return pipe will attach to your existing pool return line. For a truly professional-looking installation, take time
If your pool plumbing is 1-1/2” and you are running 2” to clean the white PVC pipe. Use a clean rag and pour
plumbing to your solar system, you should be using 2” PVC cleaner on it and then wipe the dirt and identifica-
valves and piping for all of your new plumbing, so you tion marks off the pipe. Do this on all exposed pipe.
will need two (2) 2”x1-1/2” reducer bushings to adapt This is also a good preparation if you plan on painting
your new 2” fittings to the existing 1-1/2” pipe. the pipe to match the house color.

19
If you are Installing mum performance from your solar investment. It also
allows you to select a maximum pool water temperature
an Automatic System so the solar system doesn’t overheat the pool. It ac-
The basic difference between the manual system just complishes this by the use of a sensor on the roof and
outlined and an automatic system is the use of a motor- a sensor installed into the pool plumbing. The directions
ized three-way valve. This three-way valve is operated included with the automatic system components will
by a differential control which uses sensors to determine direct you in the installation of the control and sensors.
if the solar system is warmer or cooler than the pool The three-way valve will be installed as described on
water. In this way it can shut the solar system off when the previous page and observing the note above.
cloudy conditions exist and thereby generate the opti-

Pressure Testing the Heliocol Solar System

Pressure testing the entire solar system provides for a system for any leaks. A drop in pressure on the pressure
trouble-free installation and takes only about fifteen min- gauge indicates a leak in the system.
utes. Any weak PVC glue joints, fittings or pipe, any im-
8. If there are leaks, open the ball valve on the return
proper collector clamp connections, will be evident while
line to relieve the pressure. Repair any leaks. Repeat
the system is put under 40 to 50 pounds of pressure.
the pressure testing procedures as needed.
1. Allow ample time for all glue joints to dry completely.
9. Return the system to normal when through with
Use this time to wrap up things and to clean up the job
pressure testing. Be sure to open both ball valves
site.
and replace the pressure test “T” assembly with the
2. Wrap the threads of the 142 pressure test “T” Assem- vacuum breaker.
bly, 140 ½” ball valve and 141 pressure gauge with Tef-
lon tape. Temporarily replace the 121A vacuum breaker
with the 142 pressure test “T” assembly. Thread the 140
½” ball valve and pressure gauge into the pressure test
“T” assembly.
3. Attach a garden hose to the ½” ball valve. Make sure
the ½” ball valve is in the off position. (142)

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 water, turn
off the pool pump or turn the three-way valve to by-pass
the solar system. Quickly turn off the ball valves on
both the feed and return lines.
(141) (140)
6. Turn on the city water to the garden hose and open
the ½” ball valve on the pressure test “T” assembly until
the pressure gauge reads 40 to 50 PSI and then turn off
the ½” ball valve. Turn off the city water.
7. With the system under pressure, check the whole
20
 Operating and Check-Out Procedures
Congratulations: If you carefully followed the steps in 6. When the solar system is running, you should notice:
this manual, you now have an efficient, professional-
• A slightly higher pressure reading on the pressure
looking Heliocol solar pool heating system installation.
gauge.
• At midday, if the sun is out, warmer water should
Final Visual Inspection: be coming into the pool. This water should be 3 to
5 degrees warmer than the pool temperature. Use
Since you passed your pressure test at this point, lets
the back of your hand to better feel the difference in
visually walk down the entire system and check the fol-
water temperature.
lowing items:
• All the collectors should feel cool to the touch when
1. Verify that the check valves, control valves and
the sun is on them. (If they are not, see the trouble-
vacuum breakers are installed properly.
shooting section.)
2. Verify that all plastic collector clamp clips are tight.
7. During the cooler months of the year, it is essential
3. Verify that all lag bolts are secure and that adequate that the pool surface be covered at night with a “pool
sealant was used to prevent any roof leaks. blanket” to maintain a comfortable water temperature.
4. Be sure all collector riser tubes are snapped into Low nighttime temperatures can lower the water tem-
the spacer bars (except where they go around obstruc- perature more than the solar can recover during the
tions). day.

5. Be sure that collector riser tubes are NOT rubbing

on the roof surface between spacer bars. If they are, Turning the System Off
adjust spacer bars as needed to prevent this or a hole
1. Turn the pool pump off.
may develop in the riser tube.
2. Turn the three-way valve so the “closed” indicator
6. Be certain that the system will automatically drain
points toward the solar side of the valve.
down when the pump is shut off or that enough manual
drain valves have been included. 3. If isolating the collectors, close the ball valves on the
feed and return lines after you are sure all the water
7. Verify that all pipe runs are properly supported with
has drained out of the collectors and plumbing.
pipe clamps.
4. Turn the pool pump on to filter the pool as needed.

Turning the System On

1. Turn off the pool pump. That’s all there is to it. You have installed
a Heliocol solar pool heating system that
2. Turn the three-way valve so that the “closed” indica- has been tested and proven worldwide for
tor points toward the pool side of the valve.
quality and reliability. If you run into any
3. Be sure that the ball valves on the feed and return problems with your installation, or have
lines are open. any future problems, call your Heliocol
4. Turn the pool pump on. representative or our corporate office at
800-79-SOLAR.
5. Set the pool pump timer, if used, so that the pump
will run when sun is shining on the solar collectors.
Usually 10:00 AM to 4:00 PM, but this will vary with
geographic location, time of year and the compass
location of the system.

21
Installation Troubleshooting
Trouble spots may arise during the initial Install Answers:
installation of your Heliocol solar pool Be sure filter is clean. Backwash to reduce pressure.
heater. Generally the primary cause of
Locate vacuum breaker on the feed line as shown on
problems, depending on its age, is the
page 18, Fig. 15, and put a solid end cap at the end of
existing pool/pump filtration system. Prob-
the top header where the vacuum relief was located.
lems can also arise from installer error
or oversight. We are confident that your Using the (5210) ball valve on the return line, throttle
system will work effectively and efficiently back the flow to produce more back pressure on the
when properly installed and matched to system.
your existing pool/pump filter system. This
troubleshooting guide is designed to help Some of the Solar
your installation go smoothly and work Collectors are Warm to the
properly the first day and every day there-
after. Touch while Others are Cool
Diagnosis:
There are Air Bubbles in There is not equal flow through all of the collectors.
the Pool when the Solar Warm collectors indicate low water flow.

Heater is Operating Pump Answers:

Diagnosis: Be sure the filter is clean. Backwash to reduce pressure.

There may be air coming into the pump through an air The pump may not be providing enough water to the
leak on the suction side of the pump due to the pump solar system. Check water flow using a flow meter.
working harder to move the water through the solar Increase pump horsepower to maintain recommended
system. flow. If there is a suction type cleaner in the pool, re-
move it. If this eliminates the problem, use it only when
Pump Answers: the solar system is off.
Be sure pump trap lid is on tight. Install Answers:
Check the “O” ring on the pump trap lid. Clean, lubri- If the system is a single row array and there is adequate
cate or replace as needed. flow, using the (5210) ball valve on the return line to
If you have a suction type pool cleaner, remove it. If this throttle the flow back to produce more back pressure
eliminates the air bubbles, use it only when the solar on the system. This will even out the flow through the
system is off. collectors. If the array contains more collectors than
the maximum recommended on page 8 of this manual,
If you have a clear lid on the pump and can see air bub- change the array to a double row or single row split feed
bles in the trap, use a garden hose to run water over the as shown in Fig. 1.2 and Fig. 1.3 on pg 7.
lid and each joint individually to see if the air bubbles
will clear up. If there is not a clear lid, listen to pump If the system is a double row or single row split feed ar-
noise for a smoother operation. Repair any air leaks. ray and there is adequate flow, install a ball valve on the
return side of the set of collectors that are coolest to
Diagnosis: throttle back the flow through these collectors and force
If the vacuum breaker is installed on the roof, there is more water through the warmer collectors. If any section
not enough water pressure in the solar system to keep of the array contains more collectors than the maximum
the vacuum relief valve closed so it is allowing air to be recommended on page 8 of this manual, make changes
drawn into the water as it flows by the valve. as needed to correct this.

22
 Installation Troubleshooting Continued
Water Coming from the
Solar System is not as
Warm as it Should Be
Diagnosis:
The water is flowing too fast through the collectors.
Install Answers:
Test water flow rate. Refer to the Collector Data for rec-
ommended flow on page 24. Adjust the three-way valve
to by-pass some of the water.
Diagnosis:
Seasonal normal operation
Answer:
In the cooler months of the year, or on cool, windy or
partly cloudy days, the temperature rise through the
collectors may only be 2 or 3 degrees. Use the back of
your hand to feel the water temperature difference at
the pool return inlet.

23
Performance Rating
BTUs PER DAY

Certifying Organization 50 40 30 Performance Equations

.872 - 3.729 (Ti-TA) / I

Int’l Standard ORTECH 47,400 39,400 28,440
K AX = 1.00-.0316(S) - .0104(S)2
.872 - 3.729 (Ti-TA) / I
National Standard SRCC 47,400 39,400 28,440
K AX = 1.00-.0316(S) - .0104(S)2
.828 - 3.26 (Ti-TA) / I
Florida Standard 956 BTU’s/ft2 956 BTU’s/ft2 956 BTU’s/ft2
K AX = 1.00 - .11(S)
Performance Note: Solar scientists agree that there are many variables to consider when properly sizing a system. Wind condition, micro climates, flow
rates, orientation and shading of the pool and/or collectors all affect the performance of your system. A BTU rating is just one of the many factors to consider.

Head Loss Per Flow Rate Heliocol 50

Collector Rating Number
Thousands of BTU’s per day per collector
Solar Insolation
Category T(°F)
2,000 BTU/ft2 1,500 BTU/ft2 1,000 BTU/ft2
A (-9) 98.74 78.07 57.49
B (+9) 64.13 44.01 23.96
Water Temp.
C (+36) 22.91 7.64 0
Minus Air Temp
D (+90) 0 0 0
E (+144) 0 0 0

Collector Data
Collector Model 50 40 30 12.5 10
Size, Nominal 4’ x 12.5’ 4’ x 10.5’ 4’ x 8’ 1’ x 12.5’ 1’ x 10.5’
Width 47” (120 cm) 47” (120 cm) 47” (120 cm) 11.75” 11.75”
Length 152.1” (380 cm) 127” (323 cm) 91” (231cm) 151.5” 127”
Area (sq. ft) 50.0 (4.65 m2) 41.6 (3.88 m2) 30.0 (2.77 m2) 12.2 10.2
Manifold Diameter 2” (5.08 cm) 2” (5.08 cm) 2” (5.08 cm) 2” 2”
Weight (dry) 22 lbs (10 kg) 19 lbs (8.5 kg) 15 lbs (6.8 kg) 5.5 lbs 4.75 lbs
Volume Capacity 3.7 gal (14 L) 3.1 gal (12 L) 2.4 gal (9 L) .93 gal .78 gal
Workin gPressure 90 psi 90 psi 90 psi 90 psi 90 psi
Burst Pressure 270 psi 270 psi 270 psi 270 psi 270 psi
Recommended Flow 5 gpm 4 gpm 3 gpm 1.25 gpm 1 gpm

OG-100 Collector Approved

OG-300 System Approved

24
 Notes

25
Notes

26
Installation Manual
Heliocol is the first and only solar pool collector in the world to achieve the
elite status of ISO 9001:2008 certification. Relatively few manufacturers have
the priviledge of placing the ISO 9001:2008 emblem on their products. Only
those companies performing at the highest levels in their industries can meet
the stringent requirements specified by this demanding international stan-
dard. The technical and engineering expertise of Heliocol and their relentless
pursuit of continuous product improvement have earned them the world-
renowned ISO 9001:2008 certification. Over the two-year process necessary
to gain certification, their customer service record, product failure rate and
engineering processes were all carefully scrutinized and found deserving of
ISO 9001:2008 certification.

The solar energy system described in this manual, when properly installed
and maintained, meets or exceeds the minimum standards established by
the Solar Rating and Certification Corporation (SRCC). This certification
does not imply endorsement or warranty of this product by the SRCC.

Heliocol solar pool collectors are NSF-50 certified. This certification ensures
that the water passing through the collectors will be free from unacceptable
levels of contaminates and will continue to perform effectively under the
intended use conditions.