Fully Aboveground Installations

Transcription

1 INSTALLATION INSTRUCTIONS Fully Aboveground Installations Partially In-Ground Installations Fully In-Ground Installations

2 Installation Instruction Booklet Information Endless Pools, Inc. provides for every aspect of an Endless Pool project. This manual, Installation Instructions assists in the installation process. This manual should be used in conjunction with other available resources including the Installation DVD or Video which begins with a 30 minute overview followed by step-by-step instructions of an entire installation. No installer should work on an Endless Pool installation without at least watching the 30 minute overview. We strongly encourage those involved in the installation to watch the DVD or video before beginning work. Additional available resources including The Introduction Booklet, The Planning Guide, and Technical Specifications are listed on the back cover of this booklet. A series of Technical Bulletins are packaged with the Endless Pool equipment. Copies of these Tech Bulletins are included in the Owner s Manual and online at These bulletins are referenced in the following installation instructions. In addition we encourage installers to call our Customer Service Department at (800) before beginning installation to register their project and sign up for weekend technical support. Please be advised that gloves and safety goggles should be worn during the installation of an Endless Pool. Installation Instructions Table of Contents Pool Arrival and Inspection...3 Main Drain Outlet...3 Assembly of Pool Panels (Overview)...3 Panel Assembly Instructions...3 Exploded View of Panel Assembly...4 Optional Tension Straps for Flat Bottom Pools...7 Assembly of Pool Panels with a Deeper Pool...8 Installation of Reinforcing Channels...8 Installation of the Liner Hanger...9 Valve Assembly...10 Coping...11 Options...11 Optional Bullnose Coping System...11 Optional Synthetic Coping System...12 Optional Aluminum Coping System...12 Optional Retractable Security Cover System...12 Optional Solar Blanket Roll Up System...13 Optional Tension Straps...13 Optional Hydrotherapy Jets System...13 Optional Underwater Lights System...14 Optional Swim Current Gauge...14 Optional Corner Step...14 Optional Full Depth Stair...14 Optional Swim Mirror...15 Optional Off-Peak Power...15 Optional Natural Gas or Propane Gas Heater...15 Optional 50 Hertz Systems for International Customers...15 Optional Insulation...15 Optional Deeper Platform...16 Optional Stainless Steel Floor Structure...16 Felt Underlayment...16 Liner...16 Installation of Stainless Steel Internal Components...17 Thru-wall Connections...18 Plumbing the Pool and Water Quality System...21 Water Quality System Electrical Connections...22 Power Unit...22 Bonding and Grounding...22 Hydraulic Run Hoses...22 Adding Hydraulic Fluid...23 Start-Up and Maintenance

3 1. Pool Arrival and Inspection The Standard Endless Pool arrives in three packages: a skid of 6 pool panels weighing approximately 850 lbs., a 4' x 8' x 4' high crate weighing about 1,150 lbs and a pair of 6 5 /8" wide steel reinforcing channels. Most shipping companies will lower the containers to the ground with a hydraulic lift gate on their truck; the pool can remain in the containers until you are ready to begin installation. Please contact our shipping department prior to shipment to answer any questions you may have. Since every delivery is slightly different, and depends to a large extent on 2. Main Drain Outlet Most municipalities recognize our pool wall suction fitting as an appropriate drain however some municipalities, notably in Florida, may require a main drain outlet in the floor of your pool. If you know this is a requirement the main drain needs to be positioned prior to pouring concrete. Refer to Tech Bulletin #16A for more information. To obtain a main drain please call your sales person or our Customer Service Department. If you are installing an Endless Pool on an existing concrete slab and your municipality requires a main drain outlet in your pool floor please call our Customer Service Department for details. 3.Assembly of Pool Panels (Overview) Bolt the panels together as shown on the video leaving access at the front of the pool for service. If jets, lights and/or a retractable security cover are to be installed, outside access to additional walls will be required. Access requirements are described in the Technical Bulletins, Technical Specifications and in The Endless Pool Planning Guide. Packed in the skid of panels is the Pool Panel Hardware Kit, see Figure 3.1, that contains all of the pieces necessary to assemble the pool panels and anchor them to the concrete floor. Also found in the kit is Tech Bulletin #2 describing this simple assembly and a list of all the parts in the Pool Panel Hardware Kit. Fig 1.1: Pool crate, panels and channels shown as they will arrive. site conditions, it is important to speak with our shipping department well in advance to reduce the chance of surprises. Please refer to Tech Bulletin #1 for a detailed discussion of shipping and the choices available. Upon arrival, the packages, see Figure 1.1, should be inspected for external damage. Should there be visible damage, you must complete a damage-claim report provided by the truck driver. Please call the Endless Pools shipping department immediately at (800) The pool components are not damaged by freezing conditions and may be stored outside under a tarp for an extended period prior to installation. See Figure 1.2. Fig 3.1: Hardware in Panel Kit. If anchoring down to the concrete is impractical and you have a flat-bottom pool, you may have selected optional Tension Straps. If they were ordered with the pool they would be packaged in the pool crate. Instructions for their use are included in Tech Bulletin #2. When an Optional Deeper Endless Pool has been selected, the panel enclosure will be anchored down to the concrete and there will be a concrete pad with a formed deeper section inside the panel enclosure. This is shown well in the Installation Video. Tech Bulletin #2 also includes instructions for this type of installation and an order form for a Custom Deeper Pool Liner. Fig 1.2: Outdoor storage with tarp. To begin installation, or to move pool components, begin unpacking the pool. Using a hacksaw or tin snips, remove the steel packing straps encircling the pool panel skid. The wooden top and sides of the crate may be removed with a phillips-head screwdriver. 4. Panel Assembly Instructions On a level concrete slab assemble the 6 wall panels. The smooth wall of each panel should face inward. See Figure 4.1. The front panel-the panel towards which you will be swimming-has cutouts for the skimmer, drain, water-return fitting, and 2 hydraulic hoses. Leave at least 18" of clearance from the front panel surface for the 3

4 EXPLODED VIEW OF PANEL ASSEMBLY NOTE: 1. ALL PANELS ARE 14 GAUGE STEEL WITH A 2 1 /2 OUNCE (G235 CULVERT STOCK) GALVANIZED COATING. (2) REINFORCING CHANNELS 11 GAUGE 6 5/8"(I.S.) x 11'-4" LG. (10) GUSSETS 14 GAUGE 3 7/16" X 6 5/16" X 9 3/4" (1) 7', 8', 9', or 10' LONG ACCESS PANEL (4) 6', 7', or 8' LONG PLAIN PANELS (4) OUTSIDE CORNER ANGLES 14 GAUGE 1 1/2" X 1 1/2" X 39" 6 1/2" TOP RAIL (1) 7', 8', 9', or 10' LONG ACCESS PANEL BASE RAIL 3'-6" (TYP.) (4) OUTSIDE SQ. CORNER CAPS 14 GAUGE 1 1/2" X 1 1/2" X 6 7/16" Z-BRACE 3 1/2" 14 24" ON CENTER PER PANEL NOTE: THESE DRAWING DIMENSIONS COMPLY WITH THE NATIONAL SPA AND POOL INSTITUTE SUGGESTED MINIMUM STANDARDS FOR RESIDENTIAL POOLS. FOR INFORMATION CONCERNING NSPI MINIMUM STANDARDS, WRITE: NATIONAL SPA AND POOL INSTITUTE, 2111 EISENHOWER AVENUE, ALEXANDRIA, VA (703)

5 Fig 4.1: Pool Panel and Hardware Kit. top 24" of the pool panel for access both during and after installation. Only 8" of clearance is required for the bottom 18" of the front panel and 7" of clearance is required for the other 3 sides of the pool disregarding for the moment the requirements for access for jets, lights, or the retractable security cover. Fig 4.4: Loosely bolt together the corner angle, top corner angle, gusset and panel. On the long sides, the end flanges of the 2 adjoining panels bolt together directly. See Figure 4.2. The 4 corners of the pool are held together by 4 outside corner angles each 39" long. See Figures 4.3 and 4.4. Install the 10 gussets at every panel intersection 1 on each side, see figure 4.2, and 2 in each of the 4 Fig 4.2: Long side end flanges bolted together with a gusset. The 6 wall panels will form a pool enclosure with inside width of 7' 0", 8' 0", 9' 0" or 10' 0" and inside length of 12' 0", 13' 0", 14' 0", 15' 0", or 16' 0" depending on the pool size selected. Each panel has a 3-1/2" bottom flange and a 6-1/2" top flange. Consequently, the outside bottom dimensions of the pool are 7" greater than the inside dimensions and the outside top dimensions are 13" greater than the inside dimensions. Fig 4.5: Completing pool enclosure. Note cut-outs on front panel. corners, see Figures 4.3 and 4.4. Do not install these gussets between the panels. Install the 4 top corner angles in each of the 4 corners. See Figures 4.3 and 4.4. Loosely bolt together the entire enclosure, see Figures 4.5 and 4.6, then check that the top flange of each panel is flush with its neighboring panel before tightening the bolts. Check that the panels come together evenly at the corners. There is some play in the bolt holes to allow for adjustment. End Flange Gusset Top Corner Angle Outside Corner Angle Fig 4.3: Outside corner angle, top corner angle, gusset and panel end flange shown. Fig 4.6: Bolting the pool enclosure together. Note cut-outs on front panel. 5

6 Fig 4.7: Drilling through foundation to secure blocking angle. If the pool is to be positioned next to a wall some bolts will be hard to reach. In this case, one side may be bolted together first and then slid back against the wall. You will probably want to use blocking angle rather than anchor bolts for this inaccessible condition. See Figures 4.7 and 4.8. The use of these angles is shown in the video and is described in Tech Bulletin #2. Take care when sliding the enclosure against a wall to leave enough Fig 4.10: Rigid foam insulation being installed between the support struts. panels are straight. Then measure both diagonals. See Figure Shift the panels by pushing at the corners until the difference is less than 1/8". Care should be taken to ensure that the pool is square before securing the panels to the concrete. The bottom flange of each panel has pre-drilled holes to accept the 3/8" x 3" anchor bolts Fig 4.8: Blocking angle installed with pool panel pushed flush against it. room for the coping and for the 18" of access at the front. If rigid foam insulation is to be applied on the walls of the pool, which is recommended, be sure to install it before sliding the enclosure against the wall. See Figures 4.9 and Once the panels are bolted together to form the pool enclosure make sure that the enclosure is square. First check that the long walls made from 2 Fig 4.11: Checking the pool for square. provided. See Figures 4.12 and An absolute minimum of 10 anchor bolts are required as described in the Installation Video. See Figure When possible more anchor bolts should be used with an emphasis on the centers of the panels and the center of the long sides of the pool enclosure. See Tech Bulletin #2, page 2 for anchoring information. Now insulate the Fig 4.9: Measure and cut rigid foam insulation to fit between support struts. Fig 4.12: Drilling to secure anchor bolts. 6

7 Inc. for any size pool. The kit for a standard 7' x 14' pool consists of 4 stainless steel tension straps, 1 long (14' 7") and 3 short (7' 7"). These straps run under the bottom flanges and along the floor, connecting to the outside lips of the flanges on each side (Tech Bulletin #2, page 3). See Figure 5.2. They are designed to resist the hydrostatic force of the water in the pool. Assemble the panels as described above placing the Tension Fig 4.13: Anchor bolts installed securing pool panel to the foundation. remaining pool walls with rigid foam insulation. See Figure 4.9 and We would strongly recommend insulating the walls of the pool. Please note that the insulation boards should not be used under the pool as the anchoring system will be compromised. Insulation under the pool has only a marginal value, as the heat transfered is not lost. If you wish, with new construction, you may lay down rigid foam insulation prior to pouring the concrete slab. Fig 5.2:Tension straps in place under pool. Straps under the bottom flange. The vertical lip of the bottom flange of each panel has pre-punched holes to accept the 3/8" nuts and bolts which are used to secure the tension straps. See Figure 5.3. This is the same hardware used to bolt the panel enclosure together. The Tension Straps should connect between the centers of opposite panels and at the joint in the long walls. Tighten the nuts and bolts securing the tension straps before sliding the pool into a corner. See Figure 5.4. If a strap bows up check the dimension of the pool enclosure at the bottom as the MINIMUM ANCHORING PLAN Fig 4.14: Minimum anchor bolt placement. 5. Optional Tension Straps for Flat Bottom Pools When the deeper pool option has not been selected and it is desired not to drill into the concrete floor, Tension Straps may be used. See Figure 5.1. These are ordered from Endless Pools, Fig 5.3: Connecting pool bottom outside flange and tension strap. panels may be bowed in. If necessary, you may loosen a tension strap bolt on the accessible end of one tension strap and pull the strap taut. Be sure to keep the nut and bolt in place and tighten them as you fill with water and the panels push outward. Fig 5.1: Optional tension straps. 7

8 The bottom flange of each panel has pre-drilled holes to accept the 3/8" x 3" anchor bolts provided. See Figures 6.1 and 6.2. An absolute minimum of 10 anchor bolts are required as described in the Installation Video. See figure 6.3. When possible more anchor bolts should be used with an emphasis on the Fig 5.4:Tightening the tension strap bolts. 6.Assembly of Pool Panels with a Deeper Pool When the deeper pool option has been selected, tension straps cannot be used. The anchor bolts provided with every kit must be used for these installations. They secure the panels to the concrete through the holes in the bottom flanges of the panels. See Figures 6.1 and 6.2. Ensure that the pool is square before securing the panels to the concrete. Also be sure that an adequate shelf is present on each side and at the front and back for MINIMUM ANCHORING PLAN Fig 6.3: Minimum anchor bolt placement. centers of the panels and the center of the long sides of the pool enclosure. See Tech Bulletin #2, page 2 for anchoring information.with the deeper area pool, it is critical that the panel enclosure be installed correctly so that your custom liner will fit. Please refer to Tech Bulletin #2 for details of the deeper area. EPI will make a liner only after receiving a completed copy of the Liner Order Form which is typically filled out once the panels are installed. This Order Form should be completed in full and faxed to EPI Customer Service at Allow 3 weeks for delivery of the custom liner. While awaiting the custom liner the installation and finish work may proceed. 7. Installation of Reinforcing Channels The 2 channels, each 6 5 /8" wide, fit over the top flanges of the two long sides of the pool. The channels bridge the joint between the panels on the long walls. Check that the enclosure Fig 6.1: Drilling through foundation to secure anchor bolts. the stainless steel benches which will be installed later. If an Optional Full-Depth Stair has been ordered the shelf the last step lands on must be at least 60". See further discussion of this in Optional Full-Depth Stair, Section 22 and in Tech Bulletin #10. Fig 7.1: Installing the structural channels. Fig 6.2: Anchor bolts installed securing pool panel to the foundation. is square. Put the channels on loosely. See Figure 7.1. Check to see if either channel has a sharp edge or burr and be sure to locate this on the outside face of the pool or file it down and/or cover the sharp edge securely with duct tape. The channels will be secured down later with the self-drilling fasteners provided in the liner hanger kit. These channels are structural and must be installed correctly to withstand the hydrostatic load. If you have 8

9 any questions regarding these channels or their placement, please call Customer Service. When possible, the walls of an Endless Pool should be braced laterally before filling with water to reduce outward deflection when the pool is filled with water. The steel reinforcing channels supplied by Endless Pools Inc. are sufficient to withstand the hydrostatic load but the pool walls will deflect slightly without bracing. When a rigid coping such as tile is planned this deflection is undesirable. For in-ground or partially in-ground Endless Pools simply brace or shim laterally back to the walls of the pit before filling. Be sure not to brace back to a load-bearing wall unable to resist this lateral load. Please call Endless Pools Customer Service with any questions. 8. Installation of the Liner Hanger Fig 8.3: 1/8" washer shims for leveling liner hanger. If you have purchased the optional Bullnose Coping, which has a liner hanger built into it, please refer to Section 12 prior to proceeding with your assembly. Fig 8.1:Triangular liner hanger box. The aluminum liner hanger installs around the perimeter of the pool panel enclosure. The liner literally hangs from this extrusion using a bead that is heat welded into the top edge of the liner. The liner hanger system is packaged in the pool crate in a long, triangular-shaped box. See Figure 8.1. The pieces are precut and pre-mitered to fit your pool. Only one long piece on each side needs to be trimmed to length. Self-drilling fasteners are included in the kit along with a nut driver attachment for your drill. If you have purchased the optional 8" Aluminum Coping, which has a liner hanger built into it, please refer to Section 14 and Technical Bulletin #4B prior to proceeding with your assembly. Fig 8.4: Short mitered liner hanger attached to the triangular inside corner supports. Install the 4 triangular inside corner supports, using the selfdrilling fasteners provided. See Figure 8.2. Then lay out the entire system around the inside perimeter of the pool. The hanger pieces should be flush with the inside of the reinforcing channel and will protrude into the pool the thickness of the channel everywhere else. This is shown particularly well on the Installation Video. Because the height of the 2 reinforcing channels is slightly higher than the surrounding top flange, EPI provides 1/8" thick washers in the Pool Panel Hardware Kit to place under the liner hanger and shim the pieces up to the level Fig 8.2: Installing the triangular inside corner supports. Fig 8.5: Caulking the liner hanger on the top. 9

10 of the channels to keep the whole system level. See Figure 8.3. At the 4 corners, the short mitered pieces of liner hanger rest on 4 triangular inside corner supports. Once the entire system is laid out satisfactorily secure it down to the top flange through the pre-drilled holes in the liner hanger. See Figure 8.4. Over the channels, these fasteners should be drilled through the channel and the flange. You may use a pilot hole if you wish. Elsewhere, the fasteners must be drilled through the washers and the panel flange. Fig 9.2:Valve assembly attached to pool wall. Assembly is attached to the pool with self-drilling fasteners, using the nut-driver bit provided. See Figure 9.2. Tech Bulletin #3 explains all of the front panel connections Fig 8.6: Caulking the liner hanger on the bottom. Caulk the gap between the liner hanger and the panel to ensure that no water falling on the top flange of the pool panel can work its way down behind the liner. See Figures 8.5 and 8.6. (With the same objective in mind, later caulk the joint between the top of the liner hanger and the coping that you install over the entire top flange of the pool.) 9.Valve Assembly If you have purchased the optional Aluminum Coping, please refer to Section 14 and Technical Bulletin #4B prior to proceeding with your assembly. The Valve Assembly is included in a padded bag, found in the System Control Board box, with the thru-wall fittings to be installed on the front wall of the pool. See Figure 9.1. Attach the Valve Assembly to the top flange of the front panel as shown in the video. This valve controls the amount of hydraulic fluid reaching the hydraulic motor, thereby determining the speed of the water current. The Valve Fig 9.3: Remove the knob and shaft extension. including these hydraulic connections in detail; the Tech Bulletin is included in that padded bag. Remove the knob and shaft extension by loosening the 5/64" allen screw in the coupling. See Figure 9.3. Place the Valve Assembly and rubber pad provided over the top flange of the pool wall (aligning the hole in the Valve Mounting Bracket with the small hole in the flange). See Figure 9.4. Secure with 2 self-drilling screws. See Figure 9.5. Slip the shaft back through the holes and reattach. Fig 9.1: Front Panel Connections padded bag with Valve Assembly. Fig 9.4:Align the hole in the valve bracket with the small hole in the panel. 10

11 that no carpentry is touching the hoses. Use short lengths of pipe insulation to keep the hoses from touching carpentry and resonating. Please refer to Technical Bulletin #3A. Fig 9.5: Secure the valve assembly with self-drilling screws. Retain the knob, and after mounting your coping reattach with the 1/8" allen wrench provided. Retain these 2 allen wrenches for future use. Note: Endless Pools, Inc. has provided a shaft long enough for most coping systems. The installer should cut down this shaft so that the knob is close to the coping. See Figures 9.6 and 9.7. Typically, the Valve Assembly is mounted in the center of the front panel. The hydraulic hoses connected to the submerged hydraulic motor in the pool are sufficiently long, 10. Coping Once the liner hanger system is installed you can proceed with the installation of a coping system. By coping we mean any protective material that finishes off the top perimeter of the Endless Pool. The galvanized steel pool panels should not be left unfinished. The coping system that you select directly influences the appearance of the pool. Different alternatives are described in our Technical Specifications under Finishing Details in section 5. We also offer as options three alternative coping systems which are described below. The liner hanger system allows you to install the liner and internal equipment after the coping is in place. Since it is best not to undertake coping installation and a variety of external carpentry and finishing tasks with the pool filled with water, many people choose to do that work now. 11. Options An Endless Pool is usually customized to meet the needs of the end user. Pools of different lengths and widths are selected as well as deeper pools as described previously. Naturally, the installation will vary depending on the options selected so it is important to understand exactly what has been supplied. When options are sent, installation instructions are included in the package. These instructions include information from the manufacturer when relevant, and a Tech Bulletin from Endless Pools, Inc. Each of the options is also discussed more fully in the Planning Guide which was used by the customer during discussions with the Endless Pools, Inc. design professional. Below is a summary description of the available options and important installation considerations. Please review this section before proceeding with the installation to ensure that selected options have been considered. Fig 9.6: Once coping system is installed trim the valve shaft so the knob is flush. however, to move this valve off-center. Care should be taken when closing in the front of the pool to leave access to these hoses and the Valve Assembly and make certain 12. Optional Bullnose Coping System Typically used when the pool is installed fully in-ground, the Optional Bullnose Coping System allows the installer to finish with concrete and/or tile right up to the water s edge. The aluminum bullnose coping system acts as both a liner hanger and a finished edge. Endless Pools, Inc. supplies precut pieces to fit Fig 9.7:Trim the valve shaft so the control knob will be flush with the coping. Fig 12.1: Optional Bullnose coping system. 11

12 the specific pool size ordered. Included in the kit are radius corners and straight pieces to provide a finished look. These extrusions are fastened down to the top flange of the pool panels through the spacer washers and the reinforcing channels in the same fashion as the regular liner hanger system. See Figure 12.1 Please review Technical Specification 5.3 before installing this system. The installer is responsible for building a proper perimeter substrate for the concrete or tile. 13. Optional Synthetic Coping System An ideal solution for indoor installations, the Synthetic Coping System finishes off an Endless Pool quickly and easily. Typically used when the pool is installed partially or fully aboveground, the Optional Synthetic Coping System provides a finished 9-3/4 wide waterproof edge to your pool. Made of Fig 14.2 Installing the aluminum coping snap strip. over the steel channel. The system is described more fully in Tech Bulletin #4B. The coping system is delivered with your pool. It may be ordered later and shipped by UPS groundtrack for an additional shipping charge. The kit s weight depends on the pool size and comes in 5 boxes. Each coping kit contains pre-fabricated corners and straight aluminum pieces cut to match your pool size. The 8" wide profile of the coping makes it ideally suited for pools which are freestanding or partially recessed. The coping is secured to the Fig 13.1: Synthetic coping system. (Sandstone shown) synthetic boards and corner pieces with shiplapped joints, the system comes in a variety of colors. See Figure The system is described more fully in Tech Bulletin #4. The appearance of the joint and the fastening system is best described in the Full-Length Installation Video. 14. Optional Aluminum Coping System The Endless Pools Aluminum Coping Option offers a convenient method to finish off the top edge of your Endless Pool, either indoors or out. The coping, which also acts as a liner hanger, is 1-3/8" thick and comes in a sand textured white finish. The pieces are precut to fit your pool size and fit securely Fig 14.3: Installing the aluminum cover strip. top of the wall panel with tek screws, see Figure 14.1, which are concealed beneath the aluminum snap strip of the same finish as the coping. See Figure As an alternative the 6-3/8" snap strip can be eliminated and a 6" accent tile can be installed. Joints between the adjacent coping pieces are covered with an aluminum cover strip with the same finish as the coping. See Figure Fig 14.1: Securing aluminum coping system with tek screws. 15. Optional Retractable Security Cover System Our most popular option and strongly recommended, the Retractable Security Cover system protects children and pets from the pool while keeping in temperature and humidity. With some installations, suitable access for this roll up cover system is complex and should be discussed with an Endless Pool design professional during the planning stage. Tech Bulletin #5 describes the cover installation more fully and includes an order form to select the appropriate cover fabric and specify indoor or outdoor installations which in turn determines whether a rainwater removal pump is supplied as part of the kit. 12

13 Typically the cover rolls off the rear of the pool as shown in the video. Other alternatives are possible if space is limited. These are discussed in more detail in Tech Bulletin #5. The kit includes the roller mechanism for the width of pool purchased, appropriate lengths of track, an aluminum leading edge, and the rugged fabric which floats on the water surface suspended between the parallel tracks. Two steel brackets to mount the roller mechanism at one end of the pool are available. See Figure Optional Solar Blanket Roll Up System Endless Pools, Inc. supplies an 8' x 16' Solar Blanket for all Endless Pool sizes. This may serve as a temporary cover while the retractable security cover is being installed. For those who wish it to serve as a more permanent cover, a simple PVC pipe may be used to roll up the blanket for storage when the pool is in use. For this purpose, we supply PVC clips and PVC pipe long enough for your pool width. Depending on the width of the pool the PVC pipe will come in one or two pieces with a coupling attached to one end of the one piece of pipe. Using the PVC cleaner and PVC cement you received in your plumbing kit, glue the second piece of pipe into the open end of the coupling. For pools larger than 8' x 16' a larger solar blanket is available by request and shipped via UPS. Alternatively, the roller mechanism from the retractable security cover may be used in conjunction with a length of 3" diameter PVC pipe to roll up the blanket. This optional solar blanket roll up system is available from the Endless Pools, Inc. Customer Service Department. Fig 15.1: Retractable security cover brackets. The optional Retractable Security Cover system is manually powered. We believe that this system is optimal for our compact pool and when installed correctly provides a simple means of covering the pool. Automated systems are also available. If you wish to automate your system call our Customer Service Department and they can provide additional information. The aluminum track on either side of the pool is a requirement of the retractable security cover option. See Figure Covering this track is possible but increases complexity and will add to the cost of installation. Call Customer Service for details. 17. Optional Tension Straps If you do not wish to anchor the pool panels down with the 3/8" x 3" anchor bolts provided, the optional Tension Straps may be used (see previous installation instructions). They must be selected in advance and when included they will be shipped in the pool crate. Regular 3/8" nuts and bolts used to bolt together the pool enclosure may be used to secure the Tension Straps to the bottom flange of the pool panel. Installation using these straps is described more fully in Tech Bulletin #2, page Optional Hydrotherapy Jets System By providing a supplementary pump and controller and plumbing one suction and four venturi-type jets through the wall of an Endless Pool, the user can enjoy the therapy benefits of jets in Fig 18.1: Optional hydrotherapy jet kit. Fig 15.2: Retractable security cover track (on aluminum coping). addition to the variable speed swim current. See Figure Installation is relatively straightforward but roughly doubles the plumbing work required. The kit provided by Endless Pools Inc, includes everything necessary with the exception of the 1-1/2" schedule 40 PVC pipe. Detailed instructions are included in Tech Bulletin #6 along with a typical layout drawing. When jets are installed it is important to leave access to the outside of the pool panel for service. The five holes for the jets should be cut 13

14 provided before the felt and the liner are installed. See Figure Directions come with the lights which are packaged in the pool crate. See Figure These directions are also found in Tech Bulletin #7B. These lights must be installed in accordance with local electrical codes by a licensed electrician. Each light consists of a dry niche which serves as a porthole. The low-voltage light threads into this porthole outside the pool. For outdoor installations a weather resistant can is provided for added protection. A 50' cord connects this light to a transformer which in turn plugs into a switched GFI outlet. Fig 18.2: Cutting holes for optional hydrotherapy jets. before installing the liner. See Figure The hole for suction from the pool for the jets should be cut 4" below the three inline thru-walls on the front panel. If the pool is located outdoors where freezing is an issue, care must be taken with the jet system plumbing. The freeze control option should be considered under these conditions. Call Customer Service with any questions about this limitation. 19. Optional Underwater Lights System Underwater Lights are an important aesthetic option. Typically located on either the side or the end wall of the pool, these two 20. Optional Swim Current Gauge The speed of the swim current in an Endless Pool is a function of hydraulic pressure. This pressure can be read using the gauge on the power unit. Alternatively, the optional Swim Current Gauge may be plumbed into the high pressure hydraulic line and the pressure may be read poolside in PSI (Pounds per Square Inch). See Figure This pressure will correlate with swim current speed. The correlation, however, is inexact and will change as the hydraulic fluid heats up. Pressure is a good way to set the repeatable speed of the machine. A simple alternative is to use the position of the blue speed control knob. The plumbing of the optional Swim Current Gauge is described in Tech Bulletin #8. Fig 20.1: Optional speed control gauge. Fig 19.1: Cutting holes for optional underwater lights. lights thread into in niches that are installed after the liner is in place. The holes for these niches are cut using the holesaw 21. Optional Corner Step To assist with access to the Endless Pool, optional stainless steel Corner Steps are available inside the Endless Pool in any of the four corners. For a more complete discussion of access to an Endless Pool please refer to the Planning Guide. These optional steps are approximately 11" high and are secured to the internal stainless steel bench/water return system. They are easily installed using a phillips screwdriver. If you wish to order them after the pool has shipped, contact the Customer Service Department and they will ship one to the address provided. The optional Corner Step is described more fully in Tech Bulletin #9. A 6" high Corner Step is also available. 22. Optional Full Depth Stair For those needing an easier route into the pool our optional Full Depth Stair provides seven low-rise steps and a handrail. Typically installed with fully in-ground Endless Pools, the Full Fig 19.2: Underwater light package with instructions. 14

15 Depth Stair allows the user to gradually enter the water from deck height. The steps do not obstruct the swim current. The Full Depth Stair takes the swimmer down to the bottom of the stainless steel benches. If an optional deeper pool has been selected, you would step from the bottom of the stair down into the deeper area. Care must be taken to ensure that the shelf on which the Full Depth Stair rests is sufficiently large. The shelf must extend 60" from the end wall where the steps are located. Details of this design should be worked out in advance with an Endless Pools design professional. The optional Full Depth Stair is described more fully in Tech Bulletin #10. The Full Depth stair should be ordered with the pool to avoid substantial additional freight charges due to the size and weight of the box needed to ship the steps. 23. Optional Swim Mirror The Swim Mirror helps with stroke technique and makes your swimming workout fun. The Swim Mirror, described more fully in Tech Bulletin #11, is made from durable stainless steel and is attached with three stainless steel screws which are already attached to the housing just below the swim propulsion housing. When a deeper pool is selected, make sure that the shallower area extends at least 13" beyond the front bench to accommodate the Swim Mirror. Swim Mirrors are easily sent by UPS ground and may be ordered later. 26. Optional 50 Hertz Systems for International Customers International customers interested in installing an Endless Pool where 50 Hertz power is available can specify this equipment prior to shipment. Both the Hydraulic Power Unit and the Circulating Pump come in 50 Hertz configurations. Please review Tech Bulletin #13 for a description of available alternate equipment for international customers. Please note: Endless Pools, Inc. makes no representations as to the suitability of our equipment abroad. We have not applied for relevant international certification and such certification may be required. Local permitting is the sole responsibility of the buyer. 27. Optional Insulation (by others) To conserve heat and reduce operating costs we strongly recommend that the Endless Pool be insulated with rigid foam. See Figures 27.1 and Simple 2" thick rigid foam insulation boards are usually adequate and are available from any building 24. Optional Off-Peak Power Meter The Endless Pool Kit comes standard with a 5.5 KW electric heater. Whenever possible, a special Off-Peak Power Meter should be installed to power this heater. Many power companies offer special rates for off-peak power, often less than half the cost of regular power. Check with your local power company for availability. The few hundred dollar installation charge is more than offset by the lower cost for electricity. Since the heater turns on only when the 24 hour time clock turns on the circulating pump it is not a handicap to only have off-peak power available at certain times of the day. It is common with off-peak power to run the filtration and heating equipment at night. Ask your power company and your electrician about this useful option. 25. Optional Natural Gas or Propane Gas Heater When Natural Gas or Propane Gas is available, a Natural Gas or Propane Gas Heater is usually a less expensive alternative for heating the pool. To properly consider this option, review the owners manual describing the Raypak 50,000 BTU Electronic Ignition Natural Gas or Propane Gas Heater available from Endless Pools Inc. This manual is included in its entirety in Tech Bulletin #12. The Heater comes with stainless steel heat sinks and either an indoor or an outdoor draft hood. When reviewing the manual, pay close attention to rules dictating minimum clearances to combustible surfaces and the requirements for proper venting for safety. The heater must be installed by a licensed plumber. If your installation elevation is greater than 2,000 feet please call our Customer Service Department to ensure that you have received a special high-elevation gas heater. Do not install a standard heater at higher elevations or sooting may occur. Fig 27.1: Measure and cut rigid foam insulation to fit between support struts. supply house. Check with your supplier for a recommended adhesive appropriate for the type of rigid insulation that they supply. If the pool is to be installed outside in a cold climate, you might consider using two layers. Be sure to consider the danger of freezing for any pipes running outside the insulation. Fig 27.2: Rigid foam insulation being installed between the support struts. 15

16 28. Optional Deeper Platform Sometimes customers desire a deeper pool completely aboveground without excavation. This can be done by constructing a wooden platform using a drawing supplied by Endless Pools, Inc. This system is described in Tech Bulletin #14. This solution only applies to platforms that are 12" or less in height. Any platform of greater height should be designed by a local engineer. Endless Pools, Inc. can not take responsibility for the structural integrity of platforms constructed by others. Also note that deeper pools hold more water and exert a greater load on the floor upon which they rest. Endless Pools, either deeper or flat bottomed, should not be built on upper stories without a structural engineer involved who is willing to stamp the drawings. 29. Optional Stainless Steel Floor Structure The Endless Pools, Inc. optional stainless steel floor structure provides a simple cost effective alternative to a poured concrete floor system. This system is an appropriate alternative if access to your pool site is a problem for concrete trucks or the distance is too great to haul concrete. Built to fit your specific pool size, the stainless steel floor system can be used for flat bottom or deeper pools. This system has been engineered to withstand the weight of the pool for pool configurations that are partially inground or fully above ground. The stainless steel has a foam backing providing added insulation for your pool. Minimal excavation is needed for above ground or partially in-ground pools, making this the ideal solution for a speedy installation. It is delivered with your pool as a kit of parts, which are assembled on site. Refer to Tech Bulletin #14A for step by step installation instructions. Fig 30.2: Installing felt with spray adhesive. of the pool. Place seams near the walls of the pool, so that they will be covered by the stainless steel benches. Secure the felt to the floor with the spray adhesive provided. See Figure With deeper pool installations and larger pools, a second and sometimes even a third box of felt has been provided. Secure the felt to the bottom and walls of the deeper area as well as to the 30. Felt Underlayment If it is possible, finish the rest of the pool area, especially the ceiling over the pool, before proceeding. This will help ensure that the liner is not damaged, and also keep the pool water, skimmer, and filter free of construction debris. Fig 30.3: Secure the foam corner inserts with spray adhesive. floor of the pool. Do not attach felt to the steel walls of the pool. Secure the foam inserts in the 4 corners at the bottom. See Figure Foam corners are not installed in the 4 corners of the deeper section of a deeper pool. Fig 30.1: Felt kit with foam corners. Vacuum the pool floor carefully, and make sure there are no sharp bumps that might damage the liner. Take special care to remove any metal chips that may have fallen on the floor. Install the protective felt underlayment on the floor of the pool. The felt kit comes in a box with the four foam corners, a can of spray adhesive and Tech Bulletin #15. See Figure The felt is 7' x 16'. For wider pools cut pieces as appropriate to cover the floor 31. Liner Standard flat bottom pool liners are usually packaged in a cardboard box in the pool crate. Liners for deeper pools and custom-sized pools are sent separately by UPS Ground. Check to see if your liner was backordered at the time of shipment. If you have any questions call Customer Service about the status of your liner. All work around your pool should be completed before you install your liner. Take a moment to be sure you have all necessary work completed. Prepare for the liner installation. Be sure that the liner hanger, corners, panel joints and panel to base material are sealed with silicone. Tape off all holes in the pool wall (lights, jets and front panel holes) from the outside. Place a vacuum hose through the skimmer hole and tape off the skimmer hole. Figures 31.1 and The hose should be 3" 4" off of the bottom of the pool floor felt. Install the liner by starting at the center of the front panel. 16

17 Fig 31.1:Tape off all thru-wall holes and place vacuum hose through skimmer. Spread the liner in the pool enclosure. See Figure Shoes should be removed for this and all future work in the pool to avoid damaging the liner. Find the vertical seam in the liner and center it at the front of the pool as described in the video. See Figure Place the four bottom corners of the liner in the four corners of the pool. While standing in one corner, fit the Fig 31.4: Find the vertical seam and center it in the front of the pool enclosure. After verifying that the vacuum hose is off of the bottom, turn the vacuum on. When the liner is drawn back, check to see that the corners are positioned properly. If not, turn the vacuum off and reposition the liner. With the vacuum running, smooth out all of the wrinkles. When you are satisfied with the placement of the liner, start to fill with water. Fig 31.2:Vacuum in place before liner is hung. Note thru-wall holes are sealed. top bead of the liner into the slot in the liner hanger. See Figure Work your way around the pool, fitting the bead evenly into the hanger. We recommend not ending in a corner. Smooth the liner on the floor, pushing any wrinkles toward the walls. Fig 31.5: Inserting the liner in the corner of the liner hanger. Keep the vacuum running until there is about 6" of water in the shallowest portion of the pool. Turn the vacuum off and remove all tape and the vacuum hose. Continue building the interior stainless steel portion of the pool as outlined in the Owner s Manual installation instructions. Included in the box with the liner are No Diving signs. Please post these in prominent locations around the pool. The Endless Pool is shallow and must never be used for diving. Diving into the pool is a very serious hazard and these stickers are intended to warn children of the risks. Naturally, adult supervision is also critical whenever children use the pool. Fig 31.3: Spread out the liner inside the pool enclosure. 32. Installation of Stainless Steel Internal Components Remove the stainless steel front propulsion assembly from the pool crate. Attach the 2 PVC corner turning vane assemblies labeled Front Right and Front Left using the stainless steel 10/32 phillips head screws provided. These PVC turning vane assemblies are pre-drilled. Peel off all of the protective white plastic from the stainless steel. Lower the front propulsion 17

18 assembly into the front of the pool as shown on the video taking care to keep the hose ends from getting wet. Two people can accomplish this if they work carefully in stages. Be careful not to catch the liner. Carefully slide the assembly all the way to the front of the pool and make sure it is centered left to right. Peel off all of the protective white plastic from the stainless steel side benches and install them inside the pool using the side supports at the junction between two benches. See Figure On the two benches at the rear of the pool include the Rear Left and Rear Right corner assemblies. Fig 32.3: Attaching the front housing to the pool wall. Fig 32.1: Installing the side supports Peel off all of the protective white plastic from the stainless steel rear bench assembly with the perforated grill. Attach the rear base middle support to the perforated rear base using the two stainless steel 10/32 screws on top and one 10/32 stainless steel screw and nut provided with this plastic support. See Figure Lower this assembly into the rear of the pool as shown on the video. water is in the pool which will push the liner back in the corners. Once the stainless steel is in and the holes are lining up, you may continue filling the pool while you work. Stop filling three inches below the lowest thru-wall connection. Once all the screws are tight, secure the front housing with the grab bar back against the steel wall of the pool using the special corrosion resistant self-drilling fasteners provided. Use only stainless steel, self drilling fasteners provided. Do not use Tek screws which will rust. See Figure Thru-wall Connections Once the water level is three inches below the lowest thru-wall fitting, cut 3 round holes in the liner using the holes through the steel as a template and a utility knife as shown in the video. See Figure If optional hydrotherapy jets (Tech Bulletin #6) or underwater lights (Tech Bulletin #7) were selected you must Fig 32.2: Attaching the 10/32" screw and nut. Keep all screws loose until you have started all the screws. Focus first on the bottom screws as they are difficult to work on once the holes are covered with water. If you use a cordless screw gun as shown on the video take care not to over tighten the screw into the PVC. Be careful to inspect for burrs while installing these screws. If a burr occurs remove the screw and discard. We have supplied extra screws. Do not try to install the stainless steel corner covers or any optional corner steps at this time. They may fit tightly against the liner in the corners and you risk cutting the liner. Put them aside for the moment. They should not be installed until more Fig 33.1: Cut the thru-wall holes through the liner using the steel as a template. also cut these holes in the liner as well and plumb the jets system and/or install the light niches. Located in the same padded bag with the valve assembly are 2 round thru-wall fittings. Install both of these as shown on the video. One fitting takes water from the pool and is under suction and the other one returns water to the pool after filtering, heating, and purifying. The suction port is the lowest of the three inline prepunched holes. See Figure The return fitting is on the other side of the housing (the left side as you face the propulsion assembly from inside the pool). See Figure

19 Fig 33.2: Facing the propulsion assembly, the suction port is on the right side. Each of the thru-wall fittings has two rubber washers and one cork gasket. One rubber washer is placed between the liner and the steel wall of the pool. See Figure One rubber washer is placed between the fitting and the liner inside the pool. See Fig 33.5: Installing the suction fitting with the strainer attached. suction at this fitting. See Figure The safety strainer fitting is loosely installed for shipment. For the moment you may replace the round safety strainer fitting with a threaded plug with O-ring. This will allow you to continue filling the pool Fig 33.3: Facing the propulsion assembly, the return fitting is on the left side. Figure The cork gasket is placed outside the pool under the large hex nut that holds the fitting to the wall. See Figure This nut should be tightened hand tight. Ultimately, the return fitting will have an eyeball fitting installed. See Figure For the moment you may replace the eyeball fitting with a threaded plug with O-ring on the inside of the pool. The suction fitting needs to have both a small adapter and round strainer screwed into it to eliminate the hazards of Fig 33.6: Install one rubber washer between the liner and the pool wall. before completing the plumbing of the Water Quality System. Before starting up be sure to remove these plugs and replace them with the appropriate threaded pieces. Above the suction thru-wall are two thru-walls for two hydraulic hoses. The thru-wall assembly is pretightened on each hose with the appropriate amount of teflon sealant. Simply remove the hex nut, cork gasket and one rubber washer from each fitting and install them through the wall of the pool, as Fig 33.4: Installing the eyeball fitting into the return fitting. Fig 33.7: Install the second rubber washer between the fitting and the liner. 19

20 Fig 33.8:A cork gasket is installed between the outside pool wall and the hex nut done with the previous thru-wall fittings. See Figure Hand tighten the large hex nut and connect the hydraulic elbow fittings to the top of the valve assembly as shown in the drawing accompanying the valve assembly. See Figures and You may continue to fill the pool to a point three inches below Fig 33.11: Attaching the hydraulic hoses to the valve assembly. The final opening on the front panel is the rectangular opening for the skimmer. See Figure The skimmer will be plumbed to the suction fitting as shown in Tech Bulletin #3 in order to reduce the suction hazard and protect the pump in the event that the system is kept on with the water low. The final protection against Fig 33.9: Run the hydraulic hoses through the pool wall. the bottom of the skimmer opening. In the unlikely event that any of these fittings drips call Customer Service. Do not apply a wrench to any of these fittings without first calling Customer Service. Fig 33.12: Cutting the liner using the pool wall as a template. suction hazard is the stainless steel triangular shroud which installs over these inline fittings at the end of the installation. See Figure Plumb the skimmer as described in the manufacturer s literature in the box. Use the silicone provided. Fig 33.10: Hand tighten the hex nut to secure the hydraulic hoses. Fig 33.13: Installing the stainless steel shroud over the hydraulic and suction fittings. 20

21 34. Plumbing the Pool and Water Quality System Plumb the front panel suction and return lines as described in Tech Bulletin #16. All of the plumbing fittings and the glue and cleaner to accomplish this work are packed in a cardboard box labeled Plumbing Fittings which can be found in the pool crate. We have supplied short lengths of flex PVC to be used here. We have also supplied lengths of 1-1/2" PVC Schedule 40 rigid pipe for plumbing between the front of the pool and the remotely located Water Quality System (pump/filter/heater). If more rigid pipe is required for your particular installation configuration, it is readily available at a building supply store. A hardware store will probably have shorter lengths. A good hardware store will probably also have replacement PVC fittings but we have supplied extras and more are generally not needed. If you do use PVC fittings from others be sure to use deep socket pressure fittings and not drain fittings. Customers typically locate the Water Quality System so as to simplify installation and make regular service convenient. See Figure Suitable drainage should be a consideration for Locking Ring Fig 34.2:The pump, filter and standard electric heater all fasten to the PVC base. electric heater be sure to leave enough clearance so that the black locking ring on the filter has room to rotate. See Figure Natural Gas or Propane Gas Heaters will not fit on this base and are located so as to ensure safe distances from combustible surfaces and good ventilation. We can t stress enough the importance of safety when installing a gas heater. This is especially true when the heater is installed indoors. Refer to the Raypak heater manual reprinted in its entirety as Tech Bulletin #12 for specific safety requirements and recommendations. Remember, the gas and propane heaters must be installed by a licensed professional. The drawing in Tech Bulletin #16 shows how we recommend plumbing the pump/filter/heater. The layout allows each component to be removed from the system by unscrewing a union Fig 34.1: Typical plumbing and water quality system placement. both this system and for the pool itself. There is always the risk that a valve will be left inadvertently closed (when changing a filter for example) and the 24-hour timer will turn on the circulating pump and a fitting joint will fail, emptying the pool. It is best to consider these and other scenarios during installation so that proper planning can eliminate the chance that damage will occur if the system leaks. Drains or sumps in the general area are a start. It is critical to test these with a garden hose to ensure that they work and that the floor is sloped towards them. Sometimes it is necessary to channel the water by mounting a low dam to the floor. Sometimes a sump pump must be installed even though it may never be used. Every site is different but a candid discussion with the homeowner about the possibility of future leaks and where the water will go during the time it takes to fix the leak is important. The pump and filter are pre-plumbed and fasten securely to the plastic base with 3/8" bolts and self-drilling fasteners. The components can be assembled to suit your specific site but they are generally installed as shown in the drawing in Tech Bulletin #16. The heater can be located anywhere downstream of the filter. When the standard 5.5 KW electric heater is used it may be installed directly onto the same PVC base. When installing the Fig 34.3:Typical water quality system with electric heater. rather than cutting pipe. A tee with hose bib is included for draining water prior to changing the filter or simply for partially draining the pool. See Figure PVC Glue should be used on all non-threaded fittings. Clean all non-threaded fittings with the PVC cleaner supplied before applying the glue to both surfaces. Push the fittings firmly together, turn 1/8 turn, and hold for 30 seconds. Connecting PVC plumbing is very straightforward. A watertight seal at every joint takes practice, however. Should a joint leak, cut out the part and try again with fresh pipe and fittings. Teflon sealant should be used on all plastic threaded fittings but not on the threaded ring that connects 2 halves of a union. Follow directions on the sealant container provided. Do not 21

22 over-tighten plastic fittings as they will crack. Please note: Endless Pools, Inc. provides Teflon sealant as a convenience. If Teflon tape is preferred, please feel free to use that material. Either material will work. The Water Quality System Components are described in Tech Bulletin #17 (Circulating Pump), Tech Bulletin #18 (Cartridge Filter), Tech Bulletin #12 (Gas or Propane Heater discussed above), Tech Bulletin #19 (Electric Heater), and Tech Bulletin #20 (Nature2 Copper/Silver Purification System). After reviewing the literature describing each of the Water Quality System components, plumb the system together as shown in the diagrams in Tech Bulletin #16. Note: When a gas or propane heater has been specified as an option in lieu of the standard 5.5 KW electric heater, Endless Pools, Inc. supplies stainless steel heat sinks and an indoor draft hood or outdoor top depending on our understanding of the location of the heater. Some installations may require Power Venting of the gas heater, call Customer Service to discuss when Power Venting the gas heater is necessary. 35.Water Quality System Electrical Connections The Water Quality System is controlled with a 110 volt Intermatic Timer mounted on a board and described in switches and theoretically the same limitations. When wired as described above, however, the electronic ignition will be deprived of power when the pump/timer/receptacle is off and the pressure switch is redundant. Call Customer Service about these elevation limits for the equipment. 36. Power Unit Install the 5 HP Power Unit described in Tech Bulletin #22 on a level concrete floor in a sheltered area. Since this machine needs to be serviced very infrequently it can be installed remotely to reduce noise. It is often installed near the electric panel to reduce the cost of running a 220 volt line. On the wall adjacent to the Power Unit, mount the Len Gordon AS5-TD pneumatic Controller described in Tech Bulletin #23. The Controller/Power Unit requires a separate 30 amp, GFCI protected, 220 volt service. If you do not have 30 amps of service available, you can use the same circuit as the Electric Heater by wiring both pieces of equipment as detailed in the Circuit Saver instructions in Tech Bulletin #19. Have your electrician bring power to the Controller and hardwire the Controller to the 5 HP motor on the Power Unit. The AS5-TD controller is used to turn the Power Unit on and off pneumatically, using a poolside air button mounted in the coping. Be sure to connect the 5' cord with the Hirschmann connector from the Controller to the float-level switch on the pump. Do not turn on the unit without first filling the reservoir with hydraulic fluid. Do not turn on the unit without all hoses connected. Fig 35.1: 110 volt Intermatic Timer and switched outlet electrical board. Tech Bulletin # 21. See Figure This timer turns the circulating pump on and off at preset times (typically twice a day for 3 to 4 hours each). Mount this timer on a wall protected from rain above your Water Quality System and have your electrician bring 110 volt, 20 amp GFCI power to the timer. Mounted next to the timer is a 110 volt switched outlet with a twistlock receptacle. Your electrician must wire this outlet to the adjacent timer. When a gas heater is used, the electronic ignition system is hard-wired into the load side of the timer so that the heater only receives power when the circulating pump is on. The standard 5.5 KW electric heater requires a separate 30 amp, GFCI protected, 220 volt service. Have your electrician hardwire this appliance following the heater instructions in Tech Bulletin #19. The electric heater is not connected to a timer but instead senses when the circulating pump turns on using an internal pressure switch. Occasionally, this internal pressure switch will need readjusting if the level of the heater is much more than 5' below the water level. This pressure switch can only be adjusted so much and consequently the manufacturer discourages electric heater installations where the heater is located more than 5' above or below the water level. To get around this limitation, some will install the electric heater on a shelf above the equipment or add a flow switch. The gas heaters also have pressure 37. Bonding and Grounding All of the electrical equipment that we supply is UL or CSA approved and must be installed in accordance with local electric codes by a licensed local electrician. Bonding and Grounding is an important part of that process. All electrical components have bonding lugs and should be bonded together and to the steel pool panels. A bonding conductor shall be solid copper not smaller than 8 AWG and may be insulated, covered or bare. If new construction is involved where reinforcing rods are installed in the concrete under or adjacent to the pool this should be included in the bonding circuit. Each of the pieces of equipment should be separately grounded. 38. Hydraulic Run Hoses Install the long hydraulic hoses between the Power Unit and Valve Assembly at the front of the pool. See Figures 38.1 and Low Pressure Fitting High Pressure Fitting Fig 38.1: Hydraulic hoses are installed on the power unit.the fitting on the filter/fill cap is the low pressure fitting. 22

23 ed. See Figure Endless Pools, Inc. supplies a special non-petroleum fluid created for this application and this equipment. Do not use a substitute hydraulic fluid. Extra hydraulic fluid is provided for longer hose runs. Any excess fluid should be retained for future use. Tech Bulletin #25 describes this biodegradable environmental oil. Make sure that all hydraulic connections are tight, then press the air button poolside to turn on the Power Unit. Run for a minute or two then check for hydraulic leaks at the Power Unit and the pool and tighten if necessary. By pressing this air button again you can turn off the Power Unit. Make sure you can do this. Fig 38.2: Connect the hydraulic hoses to the valve assembly on the pool These hoses, described more fully in Tech Bulletin #24, are supplied by Endless Pools, Inc. to the length specified. Often they are not shipped with the pool as the exact length is unknown at the time of shipment. Please order these hoses a week before they are needed to allow shipment by UPS ground. Two hoses up to 25 feet in length are supplied at no additional charge. It is best to use hoses close to the length you need rather than simply going with the standard 25 feet. Lengths in excess of 25 feet cost $5 per foot, e.g. two 40 foot hoses cost 15 feet x $5 = $75. Remove the protective plugs and connect the 2 hydraulic hoses to the 2 ports on the Power Unit and tighten firmly. See figure 38.1 Do not over-tighten. The hose connecting to the spin-on filter on the Power Unit is the return (low pressure) hose. See Figure To ensure that the propeller turns in the correct direction, follow the drawing in Tech Bulletin #3 describing the Valve Assembly. If the hoses you ordered are too short and you need longer hoses, call Customer Service. Extra care should be taken that these hoses are cushioned when they pass by anything that could reverberate. This will ensure a quieter installation. Use simple pipe insulation and clips for this purpose. The hydraulic hoses came with a length of tubing to connect between the air button mounted on the top flange at the front of the pool and the Controller. By pushing the button at the front of the pool a pulse of air is sent to the controller which in turn closes a contactor and provides power to the 5 HP Power Unit. 40. Start-Up and Maintenance You have now completed the basic installation of the Endless Pool. Endless Pools, Inc. supplies a complete start-up kit with every pool that includes a commercial quality water chemistry test kit, start-up chemicals to balance your water, test logs to record results, a thermometer, and equipment to vacuum and clean your pool. These are packaged in the box labeled Start-Up Kit and are described more fully in Tech Bulletin #26. Also included are step-by-step instructions describing the operation of your pool and recommended maintenance. If the pool will sit for even a day filled with water we recommend that you disperse a cup of regular Clorox bleach to the water to keep the water clean. This will yield a temporary chlorine level of 1 ppm, for a standard sized pool, which will retard bacteria and algae growth for the moment. 39. Adding Hydraulic Fluid Fill the reservoir on the Power Unit using all of the oil provid- Fill Cap Fig 39.1: Power Unit fill cap is located above the low pressure fitting. 23