INSTALLATION MANUAL1387mqjaoy63qt5kuqwm9ga0-wpengine.netdna-ssl.com/wp...Cobra Panels Modular Solar Pool Heating INSTALLATION MANUAL FOR COBRA SOLAR – DRAFT (26/04/18) subject to

INSTALLATION MANUAL

Cobra Panels Modular Solar Pool Heating

1 INSTALLATION MANUAL FOR COBRA SOLAR – DRAFT (26/04/18) subject to change

Cobra Solar Parts List

Cobra Panels

Part Image

Part Description Part Number Size Panel Area (Gross)

Panel Drawing

CP26 Cobra Panel

043_CP26

1.07 x 2.42m

2.60m2

CP34 Cobra Panel

043_CP34

1.07 x 3.18m

3.40m2

CP42 Cobra Panel

043_CP42

1.07 x 3.95m

4.22m2

Required Components

Part Image Part Description Part Number Pack Size

Roof Mount Assembly

043_516

10

Cobra Rubber Coupling Assembly

272_538

10

Cobra Header to PVC Coupling Assembly 043_607 2

Cobra Roof Strap

03000037P001 20m Coils

Optional Components

Part Image Part Description Part Number Pack Size

Cobra Rubber End Cap

043_603

2

Manifold Plugs 043_521 20

VacRel® Vacuum Relief Valve 045_0283 1

Aerosolve® 305 Silicone Lubricant 300 grams

045_0450 5



Before you start

Determine the roof(s) where the panels will be installed, taking into consideration the space, orientation, roof protrusions and shading. The selected roof(s) should be exposed to the sun for the majority of the day, with minimal shading or obstructions. The best orientation for an Australian roof is outlined in the following table:

Orientation Priority Facing Roof

Best Option North Facing

Second Best Flat Roof

Third Best West

Fourth Best East

Not Recommended South Facing

Calculating how much Collector is required

To identify how much collector will be required, you must first calculate the surface area of the pool and then determine the percentage of collector required. For the average customer and installation, it is generally accepted that in cooler climates, such as Melbourne, a collector area equal to the surface area of the pool, i.e. 100% is required. In warmer climates, such as Queensland, 80% of the surface area of the pool should suffice.

Calculating the Surface Area of a Rectangular or Square Pool To calculate the surface area of a rectangular or square pool multiply the width of the pool by its length (width x length = surface area). For example if the pool is 9 metres by 5 metres then the surface area of the pool is 45 square metres (m²).

Calculating the Surface Area of an Oddly Shaped Pool To calculate the surface area of an oddly shaped pool:

Visit Google Map Developers at https://www.mapdevelopers.com/area_finder.php

https://www.mapdevelopers.com/area_finder.php



Cobra Solar Panel Sizes

Cobra Panel CP26 CP34 CP42

Header Length (L1) 1.07m 1.07m 1.07m

Panel Length (L2) 2.42m 3.18m 3.95m

Panel Area (gross) 2.60m2 3.40m2 4.22m2

Balanced Flow

Keeping a balanced flow throughout the Cobra Panel System is very important. It is highly recommended to

use no more than the suggested number of panels in a single row as shown in the table below. This is

important for both efficiency and expansion/contraction along the length of the system.

Wherever possible the return line should have the shortest possible run back to the pool to reduce heat loss as

much as possible. (Figure 1)

If the system is larger than 12 panels or across separate roofs, splitting the system is very beneficial. (Figure 2)

Never use same end return as it reduces efficiency and doesn’t allow for proper flow. (Figure 3)

Figure 1: Reverse End Return Figure 2: Double Row

Figure 3: Same End Return

Cobra Panel Maximum Panels Per Row

CP26 12

CP34 10

CP42 8



Selecting the correct sized PVC pipe for your solar array is essential to ensure the solar system runs efficiently. Selecting a pipe that is too small will result in the water flow being restricted and will unnecessarily reduce the flow rate to the collectors. A good rule of thumb is 4 litres per minute per square metre of Solar Panel. To select the correct sized pipe, use the following table as a guide:

Flow Rate - Recommended Pipe Diameter (AS 1477 Class 9)

Litres Per Minute Pipe Diameter (mm)

Less than 170 40

170 to 300 50

300 to 600 65

Please allow for all pipe work to thermally expand and contract. Depending on how the system is installed, you may have to account for both longitudinal and/or latitudinal expansion and contraction, the longer the pipe the more allowance for expansion is required. This is particularly important when installing pipes at an angle to each other. For example when pipes are joined using a 90 degree elbow, the installer should allow for both longitudinal and latitudinal expansion and contraction for both sections of joined pipes. One option is to install larger pipe clamps further away, this will allow the pipe to bend easily.

Automatic Drain Down

All Solar Systems should be installed in a manner that will allow the water to drain automatically and completely, each and every time the pump is switched “OFF”. This is extremely important as water left in the system can cause a variety of issues that may affect the integrity of your system. This is especially important in areas subject to freezing conditions.

If the system cannot be designed to automatically drain down (possibly due to a unique roof design) then manual drain down valves should be installed in the plumbing or at the end of the bottom (supply) header. If this procedure is employed, it is important to train the pool owner in the proper drain-down procedure for winter.

Systems installed on flat roofs may require additional help when draining down by opening the collector connections and manually lifting the panel to empty the residual fluid.

Plumbing Considerations



HOW TO INSTALL COBRA SOLAR

The following procedure is for pre-assembled Cobra Panels installed in a continuous run, on a standard

corrugated metal roof and utilising Cobra End Cap Assemblies.

• For a guide on how to assemble a Cobra Panel, please refer to Page 7

• For our recommendations on how to install Cobra Panels on tile roofs, please refer to Page 8

• If installing on a metal roof with a “Wide Deck”, please refer to Page 9 before beginning step 1

Step 1: Lay the Cobra Panels roughly into position side by side.

Step 2: Step 3:

Choose an appropriate position for the top roof mounts, ideally over a batten, in order to gain the best roof anchorage. Measure out a datum point for the top roof mount and mark with a chalk line. To allow for proper panel drainage back to the pool for winterisation, please ensure the line has a slight slope of approximately 25mm per 3 metres down towards the supply line. Using the panels as a guide, mark the locations of each roof mount. Ensure that the first and last mount on each Header Pipe array is positioned at 100mm to 150mm in from the Header pipe extremities. Each subsequent mount should be placed as close to 100mm to 150mm either side of the joins between panels.

Step 4: Apply a generous bead of silicone to the bottom surface the roof mount, position using the datum line (step 2) as your guide and fix to the roof using 2 x appropriate roofing screws.

Step 5: Once all bottom roof mounts are installed, drag each Cobra Panel into the seat of the Roof Mount.

Step 6: The “Cobra Rubber Coupling Assemblies” are used to fix each panel together. Push the rubber coupling onto the manifold until it is seated properly. Next, slide the adjacent Panels manifold into the available end of the Rubber Coupling until it is also home. Ensure the Hose Clamps are positioned correctly in their grooves and then tighten using a 5/16 Hex driver or screw driver. Follow this step until the top and bottom of each panel is fastened together.

Step 7:

With the system seated in each of the roof mounts and joined together with rubber couplings, push the top section of the assembly into place. Using the two screws supplied, fasten each of the assemblies together.

Step 8: The “Cobra Header to PVC Coupling Assembly” is attached to the feed and return lines of each system. Referring to your design, install one to the bottom corner of the system; this will be the Supply line. The Return line must be on the opposite side, at the top of the system to ensure proper flow. Secure the coupling to the manifold by tightening the single hose clamp.

Step 9:

Attach the “Cobra Rubber End Cap Assembly” to the final corners of the Cobra system and tighten the hose clamps.

Step 10:

It is essential that the Cobra Panel system is properly held down using “Cobra Roof Strap” We recommend a minimum of 2 straps for CP26 and CP34 panels and 3 for CP42 variants. For particularly windy areas more straps are highly recommended.

Step 11: Measure 300mm up from the bottom header pipe towards the centre of the system and mark a datum line.



Step 12:

Begin by putting a generous bead of silicone on the ridge where you wish to anchor your first strapping position. Press the Cobra strap over the silicone at least 20mm from the end. Using an appropriate roofing screw with a stainless steel washer, screw through the strap and roof. Ensure not to overtighten to avoid stripping the thread.

Step 13:

Move to the next available ridge between panels and apply silicone, pull the strap tight over the silicone and screw down using a roofing screw and stainless steel washer.

Step 14: Follow the instructions outlined in Step 13 until the full length of the Cobra system is strapped down securely. Once all panels are strapped, use snips to cut the excess length from the roll.

Step 15: Using the recommendations outlined in Step 10, measure out where the remaining straps will be mounted, making sure to be evenly spaced along the length of the system and secured as per steps 12, 13 and 14.

Step 16: With the Cobra Panel system now fully secured to the roof, you can begin plumbing the Supply and Return lines. Supply to the Cobra System must always be fed from the bottom, preferably from the point farthest away from the pool. The Return line should be to the opposite side of the Supply, at the top of the system, preferably with the shortest PVC pipework possible.

Step 17: To securely fasten 40mm PVC pressure pipe, simply make sure you have a straight cut, apply an even coat of PVC cement to the pipe and slide it into the Cobra Header to PVC Coupling Assembly. Tighten the two outer hose clamps to fasten the pipework to the Cobra Panel system.

Step 18: Run the Supply and Return lines from the roof to ground level. Please ensure that you install adequate pipe clamps/straps to support the plumbing.

Step 19:

Run the Supply and Return lines down the side of the building to the equipment pad, ensuring you use the appropriate 45° or 90° elbows and saddle clamps.

Step 20: Connect the Supply and Return lines to the existing Pool Filtration System, refer Appendix 1 ‘Connecting the Panels to the Existing Pool Filtration System’.

Step 21: Install the Drain Tube, refer Appendix 2 “How to Install the Drain Tube” for more details.

Step 22: Install the TufFilta®, refer Appendix 3 “How to Install the TufFilta® Inline Solar Filte” for more details

Step 23: If required, install a TufGauge® to accurately check the pressure of the system.

Step 24: Now that the system is fully installed and pressure checked, complete your final operating and check-out procedures found in Appendix 4 “Operating and Check-out Procedures”

Step 25: Allow 24 hours for all adhesives to set prior to pressurising the system. To pressurise the system, follow the steps outlined in Appendix 5 “Pressure Testing the System”

Step 26: If you encounter any issues, consult Appendix 6 ”Troubleshooting”



How to Assemble the Collector

The following section offers step by step instructions for assembling the collectors. Before beginning, please

ensure you have enough of the following items:

Cobra Collector Run(s) Header Pipe(s)

Twelve (12) Barb Locks per panel

Can of Silicone spray

The following section offers step by step instructions for assembling the Cobra Solar

Panels:

Step 1: Lay the top header pipe down on a clear flat surface and apply Silicone spray to

the holes along the entire length. Be careful to control overspray so as not to slip over.

Step 2: Starting at one end of the top header pipe, push the collector into the

appropriate connection ports ensuring you inspect the collector to ensure all Silicone

Barb Seals are present, clean and intact. If not, please replace it/them using one of the replacement seals

provided.

Step 3: Insert the ‘Barb Lock’ into the correlating slots ensuring the raised lip is facing towards the collector

and push down firmly until you hear a click.

Step 4: Continue this process along the header pipe until all collectors have been installed and secured.

Step 5: Lay the bottom header pipe down, spray with Silicone and insert the uninstalled end of the collector

into the appropriate connection ports, first ensuring that all Silicone Barb Seals are present, clean and intact, if

not, please replace them.

Step 6: Insert the Barb Locks until all collector runs have been secured.



Installing On Tile Rooves

Installing Roof Mounts on Tiled Roofs

This section provides steps for installing the TOP Roof Mounts on tiled roofs. Before beginning please ensure you have the following components for each Roof Mount that is to be installed:

One (1) Tiled Roof Bracket One (1) BOTTOM portion of Roof Mount

Silicone adhesive

Step 1: Lift the tile above the line marked for the Roof Mounts and slide the Roof Bracket between the two tiles in the valley of the bottom tile. Ensure the Roof Bracket hooks onto the roof batten and apply a generous bead of silicone underneath and on top of the Roof Bracket to insulate it against the tile.

Step 2: Lower the tile back down to lock the roof bracket into place.

Step 3: Slide the bottom portion of the Roof Mount onto the installed Roof Bracket, with the open rounded section facing down the roof.

Step 4: Use two screws to securely fix the roof mount to the bracket. Make sure to have all mounts attached in a straight line.

Step 5: Repeat steps 1 to 4 until all top Roof Mounts are installed in a straight line.

Figure 1 Figure 2 Figure 3 Figure 4

https://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=2ahUKEwjTwrz879baAhURhbwKHe6KAsUQjRx6BAgAEAU&url=https://www.pickapoolpart.com.au/shop/p--tremsil-870-adhesive-black-1.html&psig=AOvVaw1PJ--vaOAMduZ4EBoI18wX&ust=1524795483604633



Figure 1

Installing The Cobra Roofing Strap On Tile Rooves

It is essential that the Cobra Panel system is properly held down using “Cobra Roof Strap” We recommend a minimum of 2 straps for CP26 and CP34 panels and 3 for CP42 variants. For particularly windy areas more straps are highly recommended. Starting at the bottom of the system, find an appropriate position around 300mm from the bottom manifold and mark a datum. Using a chalk line, snap a line across the length of the system to give a guide to where the strap will be placed. Using a masonry drill, drill a pilot hole on the outside of the system as well as in-between each panel. Knock plastic wall plugs into each hole to allow for anchor points. Begin by putting a generous bead of silicone over the anchor point of the first strapping position. Press the Cobra strap over the silicone at least 20mm from the end. Using an appropriate screw with a Stainless Steel washer, screw through the strap and plastic wall plug. Move to the next anchor point and apply silicone, pull the strap tight over the silicone and screw down using a screw and stainless steel washer. Follow the instructions outlined above until the full length of the Cobra system is strapped down securely. Once all panels are strapped, use snips to cut the excess length from the roll. Follow the instructions above to fully secure the Cobra System as many times as required.

Installing Cobra On Wide Deck Metal Rooves

Installing a Cobra Panel System on a wide deck metal roof, as shown in Figure 1, can create a number of issues unless properly addressed. Less ridges means less points to properly anchor the Cobra Roof Strap. The wide valleys also do not give much support to the collector to sit flat on the roof. To overcome these issues, we recommend measuring out the positions of your Roof mounts and marking a datum with a chalk line. Using the position of the Roof Mounts and the table below, measure out the position of the Straps and mark their starting position. If installing in a high wind area, it is recommended to install additional straps to what is suggested below.

Cobra Panel Collector Length Suggested Strap Points

CP26 2.3m 2m + 1m

CP34 3.05m 2.75m + 1.4m

CP42 3.82m 3.5m + 2.4m + 1.2m

Snap a straight line the length of the system (please note that each Cobra Panel is 1.1 metres wide).

Apply a generous bead of silicone to each ridge using the datum chalk line as a guide. Place the Cobra Roofing Strap over the first bead of silicone, press down and then screw through it into the roof to firmly fix. Keeping the strap taught, press it onto each ridge with silicone applied and anchor with a screw roughly every one (1) metre. The final ridge should also be secured using a screw.

This Method will allow for a strong base for the Cobra Panel to lay flat and allow for anchor points in-between panels even if no ridge is available simply by drilling a pilot hole through the two straps and using stainless nuts, bolts and washers.



Installing Cobra Solar Around Obstacles

There are two options when you need to install around an obstacle, you can either employ the traditional PVC pressure pipe method or you can install Cobra Manifold Plugs. The decision to use either method is up to the installer, however Cobra Manifold Plugs can be a more convenient, fast and aesthetically appealing option for smaller obstructions.

Cobra Manifold Plugs

To install Cobra Manifold Plugs:

Step 1: Locate and mark the collector tubes that are in the path of the obstruction.

Step 2: Carefully strip or cut away the marked tubing and discard. Please ensure that you do not damage the remaining tubing on the panel.

Step 3: Insert the trimmed down collector and Manifold Plugs into the header pipe, first ensuring that Silicone Barb Seals on the collector and Manifold Plugs are present and intact. If not, please replace it/them using one of the replacement seals provided.

Step 4: Secure the collector and Manifold Plug/s by inserting a Bark Lock into the correlating slots and pushing down firmly until you hear a click.

PVC Pipes To use the traditional PVC pressure pipe method to circumnavigate obstacles:

Step 1: Measure the length of the obstruction and cut two pieces of 40mm PVC pressure pipe long enough to circumvent the obstacle. You may need to take an additional 4cm into consideration, to account for the PVC Pipe Couplings.

Step 2: Once you have deburred the PVC pipe(s), cement two (2) PVC Pipe Couplings to either end. Ensure that you use a good quality, multi-purpose cement.

Step 3: Connect the PVC pipes and coupling to the appropriate panels, using four (4) Clamp Ring Assemblies, see Appendix 11 for instruction on installing the Ring Clamp Assembly.

Step 4: To prevent sagging, install a 50mm (2 inch) pipe clamp on both the top and bottom pipes, this may not be necessary if the distance is less than 100mm (4 inches).



Connecting the Supply and Return Lines

from the Roof to Ground Level

This section provides simple, straightforward instructions for running the PVC pipe work from the installed supply and return lines down to the ground level equipment pad.

While these steps are useful, they cannot possibly cover every type of installation. Therefore the installer may need to get creative and adapt these steps to suit unique roof designs or unusual equipment pad locations.

Before beginning, it is important to note that:

• Return pipes should be the shortest run

• All plumbing should be as direct as possible

• Aesthetically the supply and return pipes should be kept as close to the gutters, valleys and ridges as possible

• Plumbing skills and knowledge will be required, particularly when installing over hips or valleys

• The use of plumbing fittings should be kept to a minimum

• Where possible 45° elbows should be used instead of 90° elbows, as they are less restrictive to the water flow

• All pipes should have a slight “downhill” slope to aid in automatic drain down

• If needed, pipework must be secured with additional Roof Mounts or Plumbing Clamps as the systems manual hardware is not designed to support the additional weight of the plumbing

• The four corners of the system must be secured

If the equipment pad is positioned against the house, then you may wish to connect the plumbing from the equipment pad up to the roof. This will allow you to easily identify where the pipes need to be run down the roof. If the equipment pad is positioned in a location where trenching is required, then this would not be necessary.

To connect the supply and return lines to ground level:

Step 1: If not already installed, cement a PVC 90° elbow to the return line using a high quality, all-purpose primer and cement. This elbow should face down towards the bottom header.

Please note: It is good practice to lay a rag underneath the components you are cementing. This will prevent cement from dripping onto the roofs surface and causing damage

Step 2: Moving to the Supply line, cement a PVC 90° elbow facing away from the system (see diagram in Appendix 12).

Step 3: Identify where the Supply and Return pipes will go over the edge of the roof and mark this spot with chalk. If possible, these pipes should be installed at the exact points where they will fasten into the existing system or into pipes coming from another location.

Please note: This may not always be possible. In this circumstance, the installer may need to use their skills and knowledge to modify this step.



Step 4: Accurately measure and record the distance from the Supply and Return elbows to the marked points. Ensure that you include the depth of the elbow socket in your measurements.

Step 5: Cut your PVC pipes to suit the measured lengths. Clean and deburr the pipes and insert the elbows.

Please note: Always remember to measure TWICE and cut ONCE.

Step 6: If you are not experienced in plumbing PVC pipe, it is a good idea to lay out and connect the pipes and fittings before cementing them. This allows you to identify and fix any potential errors.

Step 7: Examine the system and ensure the pipes are as short, straight, and tight to the building as possible. Once you are satisfied, go back and cement all fitting and pipework. Ensure you double check that all parts have been properly cemented.

Step 8: Adequately secure all pipe work with the appropriate pipe clamps, bolts and screws



Appendix 1: Connecting the Panels to the Existing

Pool Filtration System

The following section outlines how a typical Cobra Solar system is plumbed into the existing pool plumbing. Not every system will be like the one outlined in the diagrams below. Some will have additional equipment, a different type of filter or the pipes may be reversed. Either way, the diagram should help you to gain an understanding of the flow of water from the pool, through the system and back to the pool. These diagrams outline all of the components necessary to appropriately plumb the system. Please study and familiarise yourself with the diagram and required components.

Please note:

• Always plumb the Non-Return Valve after the filter to prevent the filter being backwashed by the water draining down from the collector when the pump is switched “OFF”

• Always use a good quality all-purpose primer and cement

• Ensure that you properly secure all pipework

• Try to keep the system as straight, tight and clean as possible

Separate Circuit Configuration



Simultaneous Configuration

Manual System



Typical Plumbing Schematic – Filtration, Solar and Pool/Spa Heating

Typical Plumbing Schematic – Filtration and Solar with Variable 3 Speed Pump





Installed Drain Tube

Appendix 2: How to Install the Drain Tube

The following section outlines how to install the Drain Tube. Installing a Drain Tube will allow the collector and supply pipes to automatically fully drain back to the pool when the pump is switched off.

Before beginning please ensure you have:

Two (2) Grommets

Two (2) Header Barbs

Two (2) Collars

One (1) 150mm (approx.) length of tube

To install the drain tube:

Step 1: Mark the location of Drain Tube. The Drain Tube should be installed between the supply and return pipes approximately one metre above pump level.

Step 2: Drill an 8.5 mm hole in the PVC supply and return pipes in the appropriate position and orientation.

Step 3: Ensure the drilled wad, swarf and burrs are removed to prevent them from entering the system.

Step 4: Insert the rubber grommets into the holes tapered end

first.

Step 5: Insert the short end of the header barbs into the grommets.

Step 6: Slide the two Collars over the collector tube with the lips towards the cut ends.

Step 7: Push the collector tube onto the barbs.

Step 8: Slide the collars over the tube and barbs.

Please note: Dipping the components in soapy water can make this process easier.



TufFilta®

Appendix 3: How to Install the TufFilta®

This section outlines how and where to install the TufFilta®. For systems that employs a separate solar pump, independent of the pool filter circuit, it is recommended that a TufFilta® is installed on the discharge side of the solar pump.

It is recommended that the TufFilta® be positioned to allow for easy access during maintenance and away from any equipment that may be affected by pool water overflowing or splashing during the replacement of the internal cartridge element.

If a TufFilta® is installed, an isolating valve should be positioned on the

discharge side, this enables the cartridge element to be removed and replaced without drenching equipment or the person performing the task.

It is recommended that during the swimming season, the TufFilta® should be checked for debris at least once a month or as often as required for the particular installation. If you notice debris collecting in the TufFilta® it is recommended that the cartridge be replaced and the bowl cleaned.

TufFilta® Installation Recommendations

When installing the TufFilta®, please ensure that is oriented correctly (as per the image above) and that the flow direction arrow (located on top of the TufFilta®) is facing the correct direction.

Please Note: most installers incorrectly assume that the solar pumps standard lint pot is sufficient to protect the solar system from blocking with foreign matter. However, experience in the field has extensively proven that this is not the case. It should be noted that Australian Standards AS 3634-1989 Section 6.2 clearly state that "A filter or strainer shall be provided to remove solids or debris from the water entering the solar circuit.”



Appendix 4: Operating and Check Out Procedures

The system should now be installed and pressure checked. Before switching the system on, it’s a good idea to do one final visual inspection. Walking down the entire system, check that:

• The fittings and fixtures are primed and cemented properly

• All valves are installed correctly and in the right positions

• The system properly secured to the roof in a manner that will still allow for thermal expansion and contraction

• No part of the panel is rubbing against the roof surface. If it is, it can cause damage to the roof and/or panels

Appendix 5: Pressure Testing the System

Commissioning the system is one of the most important steps for any solar installation, it should highlight any faults within the system prior to hand over.

To pressure test the system:

Step 1: Allow 24 hours for all PVC Cements/adhesives to set prior to commissioning the system. This time can be used to clean the job site.

Step 2: Prime the pump by filling the lint pot with water, once filled start the pump via the manual mode on the Digital controller.

Step 3: Once primed, air should purge from the system and back to the pool via the pool return outlet for only a short period of time.

Step 4: After a minute or two inspect the pools return outlet. If bubbles continue to flow endlessly, it may be an indication that air is entering the system via the VacRel® see Appendix 21: ‘Troubleshooting’ for the solution.

Step 5: Once the bubbles reliably stop, check the TufGauge® Pressure Gauge is reading between 50 and 100 kPa (7 and 14.5 PSI).

Step 6: Check the system and panels for leaks. The suggested method is to inspect the roofs surface for water dribbling towards the gutters. By following the dribbles up the roof you will generally find the source of the leak. Repair and re-test as necessary.

Step 7: Once you are satisfied that the system is running properly, switch it off and listen to the VacRel®. Air should be entering the system through the VacRel® and water should be draining back to the pool



Appendix 6: Troubleshooting

During pressure testing or check out procedures, you may encounter some issues. The tables below should be able to help you overcome these issues:

Air Bubbles are appearing in the pool returns when the system is running

Cause:

Air bubbles are a result of air entering the system. This could be caused by air entering through the pump or through the vacuum relief valve, you can find out what the cause is by:

• Listening to the pump if the pump is making a lot of noise, then it is likely that air is being sucked into the system through an air leak on the supply side of the pump. This makes the pump work harder trying to move the water through the system and therefore it will make more noise as a result.

• Listening to the VacRel (Vacuum Relief Valve) inspect the VacRel by listening for the sound of air being sucked back into the system. This is caused by insufficient water pressure in the system which is stopping the valve in the VacRel from closing and therefore allowing air to be drawn into the water as it flows by the valve.

Solution:

When air is entering through….

The pump The vacuum relief valve

• Check that the pumps filter basket lid is on tight. If the lid is on tight, but you still suspect air is entering through this point, remove, clean, lubricate or replace the O-ring on filter basket as needed

• If the pump has a clear lid, look inside and see if air bubbles appear. If they are present, use a garden hose to run water over the pumps lid and joints and look to see if the bubbles stop. If they stop, locate and fix the leak. If the pump does not have a clear lid. Listen to the pump noise for a smoother operating sound, locate and repair any leaks

• If the pool is using a suction type pool cleaner, try removing it to see if the air bubbles clear up. If they do, only use the cleaner while the system is turned “OFF”

• Being careful not to lose any of the components, remove and clean the VacRel as needed

• Clean the filter and backwash to reduce pressure

• Adjust the (HBV) on the return line to increase the back pressure on the system



When running my hand over the panels, some areas are hot to touch

Cause:

While conducting your ‘Operating and Check out Procedure’, you were instructed to run your hand over the system to see if any part was particularly hot to touch. While it is normal for the top of the panels to be warmer than the bottom, no part of the panel(s) should be hot. Hot spots indicate that there is no/low water flow through this part of the collector. This can be due to two factors, issues with the pump or improper installation, you can find out what the cause is by:

• Checking your calculations go back and check that you have calculated and selected the right sized pump for your particular installation. If you have not, then this is likely to be the problem.

• If your calculations are correct then your issue is most likely going to be due to improper installation

Solution:

When the issue has been identified as:

The pump Improper installation

• Be sure that the filter is clean and backwash to reduce pressure

• The pump may not be big enough to provide the system with enough water. You can check this by using a flow metre. Increase the pump horsepower as required

• If the pool is using a suction type pool cleaner, try removing it to see if this eliminates the issue. If it does, only use the cleaner while the system is turned “OFF”

• If the system is a single row array with adequate flow, try adjusting the (HBV) back on the return line to provide more back pressure and even out the flow throughout the panels

• Check that you have not exceeded the maximum allowance of collectors for a continuous row. If you have, than change the array to an appropriate double row or single row split feed configuration

• If the installed system is a double row or single row split feed system with an adequate flow, try installing a ball valve on the return side of the set of panels that are the coolest to the throttle. Adjust the ball valve to back the flow through the system and force more water through the warmer panels.



The water coming from the return outlets of the pool is not as warm as it

should be

Cause:

When putting your hand in the pool water and using the back of your hand to feel the temperature of the returning water you notice it is not coming back warmer, it may be an indication that water is flowing too quickly through the system. If water is flowing too quickly, it will not get enough time to properly heat up before it is returned to the pool.

Solution:

Adjust the three-way valve on the return side of the system to push the water back up into the system. This will give it more time to circulate and heat up.

It is also important to note that the pool water will not increase in temperature as much during the cooler months of the year, or on cool, windy or particularly cloudy days. This is due to normal seasonal operation changes and cannot be helped.

Documents

INSTALLATION MANUAL1387mqjaoy63qt5kuqwm9ga0-wpengine.netdna-ssl.com/wp...Cobra Panels Modular Solar Pool Heating INSTALLATION MANUAL FOR COBRA SOLAR – DRAFT (26/04/18) subject to