Boss Solar Rhino PAR3 Page 9 Installation Manualline And Training Manual Download | Manualshive

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Revision Date: 02/07/2020

Revision: C

Pre-Assembled Rhino - Installation Manual

Definitions

What Is a Bank of Panels?

A single Bank of panels is where a set of multiple panels of the same length are interconnected at both the Top
and Bottom Headers by a Ring Clamp assembly only.

When panels Banks are separated by PVC pressure pipe, the system has more than one Bank.

What is an Array?

A single

Array

is an interconnected lot of Panels (may be various length panels and may be mounted on

different roofs) with ONLY One Supply Inlet and ONLY One Return Outlet.

What Is an Extension?

If Banks of panels are interconnected at more than TWO connection points, then any additional
interconnection is referred to as an

Extension

.

What is a System?

A system refers to the total solar pool heating system to heat one volume of water.

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Summary of Contents for Rhino PAR3

Page 1: ......

Page 2: ...ility for any injuries or death whilst installing this product For information on safe working in your region visit your state worksafe website Relationship to Boss Product Warranty Whilst Boss Solar s warranty is limited to covering the Rhino systems using Boss components Boss acknowledges that there are a number of highly regarded professional Installers whose installations may not strictly adhe...

Page 3: ... Roofs 21 Appendix 5 Installing the Roof Mounts on Tiled Roofs 22 Appendix 6 How to Connect the Solar Panels Together Installing the Ring Clamp Assembly 23 Appendix 7 Connecting the Panel System to the Supply and Return Lines 24 Appendix 8 Installing the End Caps 25 Appendix 9 Connecting the Supply and Return Lines from the Roof to Ground Level 26 Appendix 10 Plumbing Configurations 28 Appendix 11...

Page 4: ...tem Panel to Panel Couplings PVC Pipe Coupling Co Polypropylene High Heat High Impact UV Stabilised Glass Reinforced Polypropylene High Heat High Impact UV Stabilised Polypropylene High Heat High Impact UV Stabilised CPVC Chlorinated Polyvinyl Chloride High Heat High Impact Solvent Crack Resistant UV Stabilised Number of Tubes PAR3 PAR6 30 60 Tube Outside Diameter 10 5 mm Tube Inside Diameter 8mm ...

Page 5: ... Gross Collector area m 0 96 1 39 1 83 2 28 Panel Active Collector Area m 0 7 1 1 1 5 1 9 Panel Aperture Collector Area m 0 8 1 2 1 6 1 9 Total Thermal Collection Area m 0 78 1 14 1 49 1 85 Panel Weight Dry Weight kgs 3 243 4 111 5 162 6 135 Total Water Volume Capacity litres 3 14 4 72 5 68 6 78 Panel Weight Wet kgs 6 383 8 831 10 842 12 915 Panel Weight Wet m kgs m 6 7 6 35 5 93 5 69 Rec Flow Rat...

Page 6: ...Collector area m 1 78 2 59 3 41 4 23 Panel Active Collector Area m 1 5 2 3 3 0 3 8 Panel Aperture Collector Area m 1 6 2 4 3 1 3 9 Total Thermal Collection Area m 1 56 2 26 2 97 3 69 Panel Weight Dry Weight kgs 6 33 8 06 10 15 12 09 Total Water Volume Capacity litres 6 39 9 6 11 9 14 2 Panel Weight Wet kgs 12 72 17 66 22 05 26 28 Panel Weight Wet m kgs m 7 18 6 83 6 48 6 22 Rec Flow Rate litres mi...

Page 7: ...6 Revision Date 02 07 2020 Revision C Pre Assembled Rhino Installation Manual PANEL SET PARTS ...

Page 8: ...clearance around the assembled panels to allow accessed without being walked on A Schematic Drawing should be prepared before starting any work Ensure you have accurately measured the available roof space and marked any roof protrusions or obstacle This will allow you to determine the appropriate location and orientations of your system Depending upon your installation additional plumbing material...

Page 9: ...ed by PVC pressure pipe the system has more than one Bank What is an Array A single Array is an interconnected lot of Panels may be various length panels and may be mounted on different roofs with ONLY One Supply Inlet and ONLY One Return Outlet What Is an Extension If Banks of panels are interconnected at more than TWO connection points then any additional interconnection is referred to as an Ext...

Page 10: ...9 Revision Date 02 07 2020 Revision C Pre Assembled Rhino Installation Manual Panel Sets and Balanced Flow Single Row One Array Double Row Parallel Feed Two Panel Banks Two Arrays ...

Page 11: ...on Date 02 07 2020 Revision C Pre Assembled Rhino Installation Manual Single Row Split Feed Two Panel Banks Two Arrays Series Feed Two Panel Banks Two Arrays Double Row Parallel Feed Four Panel Banks Four Arrays ...

Page 12: ...11 Revision Date 02 07 2020 Revision C Pre Assembled Rhino Installation Manual Series Feed Different Roof Slopes Two Panel Banks Two Arrays ...

Page 13: ...12 Revision Date 02 07 2020 Revision C Pre Assembled Rhino Installation Manual Series Feed Opposing Roof Falls Two Panel Banks Two Arrays Series Feed Triangular Roof Three Panel Banks Three Arrays ...

Page 14: ... as possible Figure 1 If the system exceeds the maximum number of panels per continuous row see table above or is across separate roofs splitting the system is very beneficial Figure 2 Never plumb the supply inlet and return outlet to the same end of a panel array as this will reduce heating performance as it doesn t allow for a balanced and even water flow across the array Figure 3 Panel Model Pa...

Page 15: ...pe of approximately 25mm per 3 metres down towards the supply side of the array If you are installing on a metal roof mark the line ideally over a batten If you are installing on a tiled roof ensure that the line is 50mm above the bottom of the tile to allow any built up debris above the header pipe to be washed away by the natural flow of the water If the pipe is installed too close to the bottom...

Page 16: ... lines to the panel array in accordance with the steps outlined in Appendix 7 Connecting the Panel System to the Supply and Return Lines Step 13 Install the end caps on the opposite corners to the supply and return lines see Appendix 8 Installing the End Caps for details Step 15 Run the Supply and Return lines down the side of the building to the equipment pad ensuring you use the appropriate 45 o...

Page 17: ...priate panel configuration The most common and preferred configuration is in a continuous row Remember to plan for any roof obstructions when selecting a Rhino panel configuration Select the appropriately sized Rhino Solar panel s to suit your desired configuration and mounting location Use larger panels where possible to minimise panel connections lower installation time and reduce costs Before u...

Page 18: ...Google Map Developers at https www mapdevelopers com area_finder php Ensure you select the Satellite option to view and measure your pool surface area Calculating the Size and Quantity of Rhino Panels Required The size and quantity of Rhino Panels required must be large enough and correctly positioned on the roof to heat the pool efficiently For the average customer and installation it is generall...

Page 19: ...an the normal 80mm gap between two joined panels the traditional PVC pressure pipe Pipe Spacer method to circumnavigate the obstacle is generally used 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 40mm into consideration to account for the 2 x CPVC Pipe Couplings or a further 100mm...

Page 20: ...dure is employed it is important to train the pool owner in the proper drain down procedure for winterising the system 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 Alternatively you may wish to install a Solar Controller that has an ANTI FREEZE BOIL function such as the...

Page 21: ...le of withstanding the expected external forces pressures They can be spaced anywhere along the top header to correlate with the spacing of the roof batten trusses If installing on a Tiled Roof position on the valley of the tile As a general rule for average installations position all roof mounts 50mm away from all Ring Clamp Assemblies to allow for thermal expansion contraction Exceptions apply w...

Page 22: ...g Screws Using the upper chalk string line and pre measurements as a guide Step 1 Clean and dry the roof surface where the Roof Mount is to be installed Step 2 Apply a generous blob of silicone into one upper and one lower selected mounting hole on the underside of the bottom half of the roof mount Step 3 Place the BOTTOM portion of the Roof Mount onto the roof surface using the string line as a g...

Page 23: ...tep 3 Slide the bottom portion of the Roof Mount onto the installed Roof Bracket with the open rounded section facing the appropriate orientation Step 4 If installing the top of the system roof mounts secure the bottom portion of the Roof Mount in the desired location using appropriate screws If installing the bottom of the system roof mounts DO NOT fasten them to the tile brackets so as to allow ...

Page 24: ...ither mating coupling groove Step 3 Push the two couplings together ensuring that the inserted Seal enters the opposing mating groove while placing the bottom portion of the Ring Clamp Assembly under the coupling components you are connecting Step 4 Hinge the top half of the Ring Clamp Assembly over the coupling components and squeeze the top and bottom portions together until the two 2 retaining ...

Page 25: ...exible coupling assembly is generally not required and that a CPVC Coupling should suffice Note plumbing techniques to allow for thermal panel expansion contraction in and lateral directions should be considered Step 2 On the supply side of the array bottom furthest away attach one side of the Rubber Flexible Coupling directly onto the panel array and the CPVC Coupling to the other side using the ...

Page 26: ...ing into either mating coupling groove Step 3 Push the two couplings together ensuring that the inserted Seal Ring enters the opposing mating groove while placing the bottom portion of the Ring Clamp Assembly under the coupling components you are connecting Step 4 Hinge the top half of the Ring Clamp Assembly over the coupling components and squeeze the top and bottom portions together until the t...

Page 27: ...ovements Step 1 If not already installed cement a PVC 90 elbow and a short length of 40mm PVC pressure pipe to the CPVC coupling mounted to the return outlet of the array using a high quality all purpose primer and cement This elbow should face down towards the bottom header Step 2 Moving to the Supply line cement a PVC 90 elbow and a suitable length of 40mm PVC pressure pipe to the CPVC coupling ...

Page 28: ...00 to 600 65 Flow rates should be between 1 8 to 4 8 litres per minute per square metre of installed panels however Boss recommends 4 litres per minute per square metre of installed panels to provide the best pool heating efficiency Once the required Flow Rate has been calculated select an appropriate pump size based on pump manufacturers FLOW RATE HEAD HEIGHT specifications This will ensure that ...

Page 29: ...e study and familiarise yourself with the diagram and required components Independent Separate System The pool water is pumped directly from the pool to the solar collector absorber and then back This configuration requires the pool builder to plan for solar or for solar provisions to have been pre installed It is simple to install and does not interrupt the filtration system This type of plumbing...

Page 30: ...to retro fit a solar system without affecting any other part of the pool structure A Solar Booster pump can be used to push the filtered water up to the solar absorber if required The only disadvantage with this set up is that the solar can only operate when the filtration system is operating Requires 1 x AS5CD Digital Solar Controller or similar 1 x Check Valve also known as a Non Return or One W...

Page 31: ...o plump the system However you have very limited control over the heating process and must remember to go out and adjust the valve if you want the system to operate It also puts extra load on your pump and filter and is therefore only recommend for single story installations with limited head The plumbing must be cut in before any other pool equipment e g chlorinate heat pump gas heater etc Requir...

Page 32: ...Simultaneous Retro Fit System without the need for a Booster Pump However the special controller and motorized valve are more expensive and require more effort and skill to set the valve up correctly Requires 1 x Check Valve also known as a Non Return or One Way Valve 1 x Motorized Valve 2 x PVC Tee 1 x Special Digital Controller such as the AquaSmart 5 AV controller or similar ...

Page 33: ...no solar pool heating system is in a 40mm PVC Tee Fitting on the supply line The Tee Should be glued so that the VacRel will sit vertically once installed Steps for installation Step 1 Take note of where the VacRel is to be installed Step 2 Glue a 40mm PVC Tee Fitting into its appropriate position using standard plumbing techniques making sure the upper socket is as vertical as possible Step 3 App...

Page 34: ...ed location Step 3 Clean any swarf or burrs from the newly drilled hole Step 4 Lubricate the grommet and carefully insert Step 5 On the male inch thread on the back of the TufGauge wrap several layers of Teflon tape counterclockwise Step 6 Tighten the barb onto the back of the TufGuage using two spanners or shifters Step 7 Lubricate the barb and carefully push into the grommet Pressure Testing Set...

Page 35: ...y 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 lubricate and insert the short end of the header barbs into ...

Page 36: ...n 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 replacement filters should be available through your local Boss distributor TufFilta Installation Recommendations When installing the TufFilta ensure that is or...

Page 37: ...tidy and of high quality Appendix 16 Pressure Testing the System Commissioning the system is one of the most important steps for any solar installation Performed correctly commissioning 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 cle...

Page 38: ...lling faster from the roof and back to the pool compared to the water being pumped up to the roof 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 ...

Page 39: ...entified 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 meter 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 ...

Page 40: ... the valve to slow the flow through system to bring it within specification of 4 litres min m Note restricting the flow of a pool pump may increasing the energy cost of running the pump Double check is the system has been installed correctly to provide balanced and even flow across all solar panels It is also important to note that the pool water will not increase in temperature as much during the...

Page 41: ...n a regular basis as leaks can corrode metal roofs and gutters Leaks should be repaired as soon as possible Non Return Valve The non return valve see plumbing diagrams is a critical system component Check that the collectors drain fully when the pump stops Vacuum Release Valve The vacuum release valve 9 is a critical system component It should be checked that it is functioning correctly and that t...

Page 42: ...41 Revision Date 02 07 2020 Revision C Pre Assembled Rhino Installation Manual SRCC Certification Thermal Performance Rating ...

Page 43: ...42 Revision Date 02 07 2020 Revision C Pre Assembled Rhino Installation Manual Panel Pressure Drop ...

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