HI-Deluxe Installation Manual

Read this manual before beginning to install the solar system. You will save installation time and get maximum performance from the system.

Warning

If you plan to install the solar system on a roof you must be experienced in working on a roof and have the proper safety equipment. If not, you should hire a qualified person to install it for you. Failure to observe proper safety procedures when climbing ladders or working on a roof or other raised structure can result in a fall with serious injury to you. Do not build a supporting rack for the solar collectors against a pool fence in such a way that children can climb the rack and thereby gain access to the pool.

Planning

Before beginning installation check to see that the system sizing and location criteria in the Solar System Selection Guide have been followed. If you find it necessary to undersize the system it is your responsibility to inform the pool owner to expect proportionally less heat to the pool than if the pool was sized according to the manufacturer's specifications. For example, ten percent undersized means approximately ten percent less heat to the pool.

Section 1 - Section 2 - Section 3 - Section 4

Section 1: Mounting Components

This section provides descriptions and part number of Harter Industries Installation Kits required for each solar pool heating system. The mounting location of each kit component is shown by the corresponding circled number in the Mounting Components Diagram.

1. HI-Deluxe Collector Kit (Part No. 1090-2)

Contains all parts needed to fasten down one solar collector and connect it to the next one in a row. You need one collector kit per collector. Included is: 1 Outlet Header Hold-Down Bracket Assembly (#2264), 2 Step Brackets (#8016-2), 2 Collector Coupling Hoses (3 3/4" long, #8017-3), 4 Stainless Steel Coupling Clamps (#1012).

2. Deluxe system Kit (Part No. 1091-2)

Contains parts needed to fasten down collectors, and to connect piping to a system. Use one system kit for each row of collectors in the installation. Included is: 1 Outlet Header Hold-Down Bracket Assembly (#2264), 4 Hold-Down Strap Clamp Assembly (#8023-1), 1 End Cap (#4032-2), 2 Pipe to Collector Adapter (#4033), 2 Strap Brackets (#8016-2), 2 System Coupling Hoses (6" long, #8017-6), 4 Stainless Steel Coupling Clamps (#1012).

3. Hold-Down Strap

A hold-down strap is required to secure collectors to the mounting surface. Use strap 4037-6 (54') for rows of up to 6 collectors or strap 4037-9 (80') for rows of up to 9 collectors or 4037-14 (122') for rows of up to 14 collectors.

4. HI-Deluxe Split row Kit (Part No. 1093-2)

Use this kit whenever it is necessary to split a row of collectors to clear obstructions, or to install part of a row on another roof. Included: 1 Outlet Header Hold-Down Bracket Assembly (#2264), 4 Hold-Down Strap Clamp Assembly (# 8023-1), 4 Pipe to Collector Adapters (#4033), 2 Strap Brackets (#8016-2), 2 System Coupling Hoses (6" long, #8017-6), 4 Stainless Steel Coupling Clamps, (#1012).

5. Header Inserts (Part No. 8029)

Heater Inserts are used in special situations where unusually high stagnation temperatures are expected, such as in a desert climate or where abnormally high system pressures may occur.

6. Vacuum Relief Valve Kit (Part No. 1094A)

One per system is required whenever collector inlet (bottom) headers are higher than three feet above the pool surface and with six or more collectors.

7. Check Valve

One check valve should be installed per system whenever collector inlet (bottom) headers are more than three feet above the pool.

8. Control System

Every HI-Deluxe pool heater needs a control system to by-pass the solar collectors when the pool reaches the desired temperature, or during inclement weather. In most climates an automatic control system should be used. It consists of an electronic control panel, two sensors and a motor-driven valve. In warm climates, with little rain a manual control valve may be used.

Section 2 - Installation of HI-Deluxe Solar Collectors

Step 1: Plan the location of the collectors on the mounting surface. The outlet (top) headers must be at least 8 inches higher than the inlet (bottom) headers and the row of collectors must slope at least ¼-inch per collector toward the supply pipe as shown in Figure 1. That will allow drainage that prevents freeze damage. Table B shows the amount of space needed for an uninterrupted row of collectors. Add 8 to 12 inches at each end of the row for piping. Add 2 ½ inches above the outlet header for Mounting Brackets.

Note from Figure 1 that the pipe carrying the water back to the pool (the return pipe) is connected to the collectors diagonally opposite the supply pipe to the collectors. Determine the position of the last outlet header hold-down bracket for the row of collectors. Mark this point on the roof. The collector outlet headers will be approximately 1" below this mark. See Figure 3. From the mark, snap a chalk line to the opposite end of the row. The chalk line must slope down the roof toward the supply side ¼" per collector. For example, six collectors in the row means a total slope of 1 ½ inches. See Figure 1. Using a 1/8" drill bit, drill a hole for the first outlet header bracket on the first roof mark. Measure up 1" on center from the first pilot hole and drill pilot hole for second screw. See Figure 4. Repeat this process all along the chalk line every 51 inches for the number of collectors to be installed.

Step 2: Inject a generous amount of high quality silicone or urethane sealant into each hole and onto the surrounding roof surface. Bolt all the outlet header hold-down brackets to the roof as shown in Figure 4.

Figure 4:

Step 3: Locate the hold-down strap bracket holes using the information in Table A. Measuring from the top outlet header bracket chalk line, snap another chalk line parallel to this line using the "A" dimension. The "B" dimension is the same for all collector sizes. It is 16" up from the outside of the bottom header and you can measure it after the collectors are installed. Wait until after the collectors are installed before installing the hold-down strap brackets so as not to damage the collectors when you are bringing them to the roof for installation

Figure 5:

Step 4: Bring the first collector to the roof and slip the proper hoses over both ends of the inlet and outlet headers on the last return collector. Make sure that the side of the collector with the serial number label on it is facing down. The long hoses go on the outlet of the last collector and the inlet of the first collector. Push the hose onto the collector header until it stops at the hose locating shoulder, but NOT OVER it. Install a hose clamp 3/8" from the end of the hose in order to center it on the header groove. The clamp screw must face up so it will be accessible for tightening and will not rub against the mounting surface. Make sure you securely tighten each clamp with a nut driver. If a nut driver is not available, a "hex" wrench or screwdriver will suffice. THE HOSE CLAMPS MUST BE LOCATED OVER THE GROOVES IN THE HEADER.

Step 5: Position the collector on the roof so that the centers of the outlet connection hoses are directly beneath the secured outlet header brackets and slip the bracket hold-down clamps over the connection hoses. Lightly tighten the clamp around the header hose. Refer to Figure 5. Continue to install all the collectors in the array, coupling them side to side.

Step 6: Go to the lower chalk line previously snapped on the roof for the hold-down strap brackets. Mark a hole 2" from the side of the first collector and continue marking holes on the chalk line centered exactly between the absorber surfaces until you reach the last collector. Mark the last hole the same 2" to the side of the last collector. Drill a pilot hole and apply sealant at each of these locations. Bolt the hold-down strap brackets on the roof. It is OK to step on the collectors as long as you stay one foot away from the top and bottom headers. Mark the holes for the bottom hold down strap by measuring up 16" from the outside of the bottom header, centering them between the absorbers and 2" away from the first and last collectors.

Step 7: Slip one end of the hold-down strap through a strap clamp, then through the two slots in the hold-down strap bracket at the end of the row. Pull about 3" of the strap through and bend it back toward the clamp. Slip the end the strap through the strap clamp and pull it tight. Tighten the clamp screw securely, but do not over-tighten it to the point where the clamp is distorted. Bring the strap long free end across the collector face, passing through both slots in the bracket located on the other side of the collector. Pull the strap taut against the face of the collector. Repeat this procedure for the remaining hold down strap, then connect it to the hold-down strap bracket at the end as you did at the first one.

Step 8: Install the vacuum relief valve in the outlet header. at the opposite end of the row that is connected to the collector outlet pipe. Refer to figures.

Step 9: Install an end cap in the inlet header of each row, opposite the end that is connected to the collector inlet pipe. Refer to Figures 1 and 2.

Warning: Do not attach mounting brackets to both headers of a panel. Doing so voids warranty. The reason for this is that the panel expands and contracts with changes in temperature. With brackets on both headers, falling temperature causes the panel to shrink, creating a strong force that can damage the panel. Install the mounting brackets on the outlet header only. That allows the inlet header to move slightly, adjusting to changing temperatures.

Step 10: Connect collector headers to the supply and return pipes with long hoses, coupling clamps and pipe to collector adapters. Use only universal PVC/CPVC/ABS cement between the adapter and the pipe fitting.

Step 11: It is important that you install the solar system so that it can fully drain by gravity to prevent freeze damage. The HI-Deluxe Automatic Control and Manual Control Valves supplied by Harter Industries have a small built in by-pass to allow water to slowly drain back to the pool, even if the solar system is shut off. Therefore, collectors and piping must slope toward the supply as shown in figure 1. If you cannot plumb your system so that it will drain to the supply, you must install a manual drain from the lowest point in the system on the roof.

Step 12: INSPECT THE INSTALLATION AND CHECK ALL CLAMPS FOR PROPER POSITION AND TIGHTNESS.

Section 3 - Stem Piping

To achieve optimum performance from the system, meet the recommended water flow rates in Table C. Solar systems with less than 300 square feet of collector area and located less than 20 feet from the pool may be connected with 1 ½" schedule 40 PVC pipe. All other systems should be plumbed with 2" or larger schedule 40 PVC pipe. Plan the piping to minimize the number of fittings. It is important to keep pressure losses low so the maximum amount of water flows through the collectors.

Referring to Figures 1 and 2, note the supply to the solar collectors is always at the inlet headers and the return is diagonally opposite, at the outlet headers. The three-way control valve, whether it is manual or motor driven is installed in the inlet line to the collectors.

If the collectors are installed with the inlet headers more than three feet higher than the pool, a check valve should be installed between the pool filter and the control valve. This valve prevents back-washing filter debris to the pool when the pump shuts off.

The pool water sensor for an automatic control must be installed before the control valve, so that it senses the actual pool water temperature. Drill a 3/8-inch diameter hole in one side of the filter system pipe anywhere between the filter and solar system control valve. Insert the sensor and hold it in place with the hose clamp.

Use a screw to attach the solar sensor to the same surface to which the solar collectors are attached. Make sure that the solar sensor sees the same amount of sun for the same length of time as the collectors. Do not allow the solar sensor to touch a solar collector or any pipe. Installation instructions packed with the automatic control system should be followed. Solar system isolation valves are optional and are not supplied in standard kits.

If a high-pressure pool cleaner pump is used, its supply should be connected between the filter and the control valve. If a gas or electric heater or heat pump is used, it must be installed between the solar system return tee and the return line to the pool.

Heaters and heat pumps often create an excessive pressure loss, so it is good practice to provide a bypass as shown. The bypass valve may be opened whenever the solar system alone is heating the pool (Note: some heaters require water flow at all times).

On the roof (or other mounting surface) horizontal pipes should be supported every 4 feet and vertical pipes every 8 feet. A support should be placed as close to the collector supply and return as is practical. HI-Deluxe Stainless Steel Hold Down Clamps, Part No.2264, are useful for this purpose.

Special System layout Piping:
The shape of the available space or roof obstructions often requires dividing a system into multiple rows or splitting rows. Figure 7 below shows a system divided into two rows. You will need a HI-Deluxe System Kit, Part No. 1091-2, for each added row. Note the return from the lower row is connected to the return at the highest point in the system. Slope the rows toward the supply for drainage. Figure 8 on page 7 shows a more complex, multi-level system with split rows. Roof vents can often be straddled by using a pair of long hoses in place of short ones. In Figure 8, the third row is on another roof, higher than the first two rows. Note that the returns for the first two rows meet the return from the third row at the highest point in the system. Again, slope all rows toward the supplies, so the system can drain.

With a roof vent pipe up to 3" in diameter, the collectors can be positioned on either side of the vent. You can use two system connector hoses (Part #8017-6) to couple the collectors together for vent pipes or other obstacles up to 7" in diameter. With obstructions of over 7" such as attic fans and skylights, lay out the collectors on either side of the obstruction using a HI-Deluxe Split Row Kit (Part #1093-2)

Section 4 - Start Up & Maintenance

Before starting the pump, we recommend that you install a flow meter in a location to accurately show the flow rate through the solar system. The preferred location is before the solar collectors, after at least 3 feet of straight pipe. You can then determine if the flow rate meets the level shown in Table C.

This section describes the steps for starting an automatic system. If a manual control is used, turn the three-way valve to the indicated positions. The "OFF" mark opposite the valve handle indicates the line that is blocked by the diverter.

Switch the control to "ON". The Power and Heating lights should come on and the control valve should turn to divert water flow through the solar collectors. If it does not, check the low voltage wiring to the valve motor. If the valve motor has a toggle switch, make sure it is not in the "OFF" position.

With the system on, the collectors should be purged of air in 1 to 3 minutes and the water returning to the pool should be clear and free from air bubbles. After 5 minutes, feel the return end of the absorber plate on each collector. They should be uniformly cool to the touch. If they are, you have uniform flow to all collectors. If they are not, flow must be increased to the minimum specified levels in order to get rated performance from the system. If on a multiple-row system, one bank feels warmer than the other, the flow must be corrected.

Install a ball valve in either the supply or return line to the row that feels cooler. You can then throttle this valve until the temperatures of the collectors on each bank are approximately equal.


Next, switch the control to "OFF". The valve should turn to divert the water to the pipe that by-passes the solar collectors. Switch the control to "AUTO". Set the temperature control to the maximum position, or at least 10 degrees higher than the pool water temperature. The "Heating" light should come on and the valve should turn to divert all the pool water through the solar system. If the light does not come on, disconnect the pool water temperature sensor wires and temporarily "short" the solar sensor terminals. If the "Heating" light now comes on, you probably have a bad wiring connection to the solar sensor.

Set the temperature control to the minimum position or at least 10 degrees below the pool water temperature. The "Heating" light should go out and the valve should turn to divert the water through the by-pass pipe. If it does not, disconnect the solar sensor wires and temporarily "short" the pool water temperature sensor terminals. If the light now goes out, you probable have a bad connection in the pool water sensor wiring. For further trouble shooting information, see the control and valve manuals packed with the control.

Once everything is working, set the control for the maximum desired water temperature with the control on "Auto" and enjoy your pool.

Maintenance - For pools that are closed during the winter months, if the solar system is piped in accordance with the instructions in this manual, it will naturally drain by gravity after the pump has been turned off. When all water has drained from the collector system you may follow normal pool winterization procedures. Any piping that will not drain by gravity must be manually drained or blown out, to prevent freeze damage. Low areas that can trap water should be filled with propylene glycol to prevent freezing.

For pools remaining open during the winter months, isolation valves may be installed as shown in Fig. 3. After the solar system is completely drained shut off the ball valve to isolate the system.

In warm climates where the pool is kept open all year a normal practice is to turn on the filter system with the solar system on, sending warm pool water to the collectors whenever light freezes are expected. Your control can be easily set to automate this operation whenever the pump is running. Contact the factory for details. Obviously, an automatic recirculation system works only when electricity is available.

Installation on a Tile roof Be careful not to break the tile. Do not walk on the high points of barrel tiles. At each mounting bracket location, drill through the high point on the tile with a masonry drill slightly larger than the screw (9/32 for ¼-inch screw). Then drill through the roof board with a pilot drill for the screw (1/8 for #14 screw). Attach a 5/4x4 or 1x4 pressure treated board to the roof and screw the mounting brackets to it. Use screws long enough to penetrate the roof boards and coat the threads heavily with Silicone II or RTV before installing them. At the strap bracket locations, attach 5/4x4 or 1x4 pressure treated boards to the roof as above and screw the Strap brackets to them.

Collector Repair - This method allows for an easy and permanent on-site repair of a collector by isolating the leaking riser tube, using HI-Deluxe repair kit Part No.1122. Referring to figure 9, locate the tube to be isolated. (End tube has been shown for clarity.) Using a sharp utility knife, very carefully cut away approximately 1" of the tube at both headers. Drive a screw into the hole in each header. DO NOT OVERTIGHTEN! This repair method will not void the collector warranty.