FAFCO Sunsaver User manual

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Made in the U.S.A.
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S o l a r P o o l H e a t i n g S y s t e m s
FOR USE WITH SWIMMING POOLS
TO HARNESS THE ENERGY OF
THE SUN
INSTALL A T I O N
MANUAL
SUNSAVER®

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System Overview
Theory of Operation
Specifications, Certifications & Listings
Components & Parts List
System Overview
Safety & Disclaimer
Quick Tips
PHASE I —Site Preparations & Planning
Collector Layout
Spacing Collectors and Penetrations
Plumbing Layout
Supporting PVC Pipe
Plumbing Materials
Roof Penetrations
Hybrid System Layouts
PHASE II —System Installation Detail
Mounting Collectors
Connect Supply & Return Lines
Obstacle Avoidance
VRV & End Caps
Diverter Valve
Pool Equipment Tie In
Pool Plumbing
Thermal System Automation
PHASE III —Commissioning
Diverter Valve
Pressure & Leak Check
Placement of Sensors
System Automation
Commissioning Documents
Installation Manual
Table of Contents
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PHASE IV —Routine Maintenance
Winterization
Spring Startup
Pool Maintenance
Collector Repairs
Closing Checklist
Appendix A —Commissioning & Warranty Registration
Appendix B —Pump Sizing
Pump Sizing Calculation Tables
Example Pump Sizing Calculation
Example Manufacturer’s Pump Curves
Appendix C —Reference Tables & Figures
Bank Movement Clearances
Plumbing Heat and Pressure Tolerances
Various Plumbing Configurations and High Point Return
Plumbing with Balancing Valves, No High Point Return
Plumbing Movement
Bank and Plumbing Movement
Appendix D —Roof Mounting Details
SunSaver®Collectors on Composition Roofs
SunSaver®Collectors on Barrel Tile Roofs
SunSaver®Collectors on Flat Tile Roofs
SunSaver®Collectors Wood Rack Mounted
SunSaver®Collectors Metal Rack Mounted
Appendix E —Alternate Methods of Compliance
Acceptable Installation of Valves
Installation Manual
Table of Contents
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As summer seasons approach in the year, the strength
of the Sun’s rays intensifies due to a more direct geo-
graphical exposure to the Sun. This means more and
more energy can be captured for our use which can be
harnessed and directed into swimming pools and used
to increase a homeowner’s comfort for free. Water
flows through the hundreds of small diameter tubes
System Overview
Theory of Operation
Each SunSaver®Collector consists of the Sheet or Body, the Collector Insert and a Header Pipe. The Sheet or Body is the prima-
ry portion of the collector which collects thermal energy from the Sun and may also be referred to as a Thermal Collector.
Since 1969, FAFCO®’s goal has been to design, test, and produce the world’s highest performing solar
pool heating systems.
Installing a FAFCO®solar pool heating system is straight-forward and relatively simple. This manual pro-
vides a step-by-step installation procedure for most applications. For those situations not covered in this
manual, please contact your FAFCO®representative.
Please read this manual completely before starting the installation and take special care to comply with all
local ordinances and building codes.
Figure 1 | SunSaver®Collector Make Up
constituting each Thermal Collector, taking heat from
the Sun and often even reducing temperatures of the
roof itself.
The heated water then returns to the swimming pool
to reduce, and often eliminate, the need for a pool
heater. This further reduces household energy costs.
SunSaver®
Collector
Collector
Insert
Sheet/Body
Header

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Specifications, Certifications & Listings
SunSaver®Collector Specifications
Collector Area 48ft2, 40ft2, 32ft2, 24ft2, 20ft2, 16ft2
Collector Dimensions (HxWxD) 4ft x (12ft, 10ft, 8ft), 2ft x (12ft, 10ft, 8ft)
Weight (lbs empty) 22.0 (48ft2), 19.0 (40ft2), 16.0 (32ft2)
11.0 (24ft2), 9.5 (20ft2), 8.0 (16ft2)
Roof load (lbs full) 66.9 (48ft2), 58.9 (40ft2), 50.1 (32ft2)
33.4 (24ft2), 29.5 (20ft2), 25.1 (16ft2)
Fluid Capacity (gal)
5.4 (48ft2), 4.8 (40ft2), 4.1(32ft2)
2.7 (24ft2), 2.4 (20ft2), 2.1 (16ft2)
Fluid Connection Type FAFCO®Proprietary
Chemical Resistance Chlorine and Saline Pool Compatible
Freezing Drain at 45°F prior to Freezing Conditions
Absorptivity 0.96
Emissivity 0.90
Thermal Specifications*
Thermal Energy Output 1800 Btu / (ft2-day)
System Operating Pressure (<100 °F) At Bottom Header 30 psi
System Intermittent Pressure (<100 °F) At Bottom Header 40 psi
Factory Test Pressure / Burst Pressure Per Collector 50 psi / 220 psi
Recommended Flow Rate Per Collector 0.1 gal/min/ft2
Delta T (at y intercept) 6°F
Operating Temperature Range (typical) 60-100 °F
Stagnation Temperature 160°F
*All performance data calculated at STC (Standard Test Conditions) 80 °F, 317 Btu/hr./ft2, 1.5 AM, Inlet Water of 70 °F, Wind speed=3 mph
System Overview Cont’d
SunSaver®Collectors have been certified and listed for the following:
• SRCC OG-100 #10001954
• ICC-SRCC Listing #16006

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Item Image Name P/N Description
1
SunSaver®
(4ft x 12 ft)
(4ft x 10 ft)
(4ft x 8 ft)
822 (12ft)
820 (10ft)
818 (8ft)
4ft SunSaver®Collectors. These 4ft wide Collectors are available in three
different lengths, 12ft (48 sq.ft.), 10ft (40 sq.ft.) and 8ft (32 sq.ft.)
2
SunSaver®
(2ft x 12 ft)
(2ft x 10 ft)
(2ft x 8 ft)
09523 (12ft)
09524 (10ft)
09525 (8ft)
2ft SunSaver®Collectors. These 2ft wide Collectors are available in three
different lengths, 12ft (24 sq.ft.), 10ft (20 sq.ft.) and 8ft (16 sq.ft.)
3
Vacuum Relief
Valve (VRV) 188
Black, weather resistant CPVC, 2” PVC pipe size, barbed. Seals system
when pressurized and allows collectors to drain when the system is off.
Adapts to Solar Collector using Short Rubber Coupler.
4
End Cap 05380
Black, weather resistant CPVC, 2˝PVC pipe size, barbed. Adapts to solar
collector using Short Rubber Coupler.
5
Pipe Adapter 05381
Black, weather resistant CPVC, 2” PVC pipe size, barbed female slip.
Used with a Rubber Coupler to adapt the VRV to PVC.
6
Base 06918
Black, weather resistant polymer. Mounts solar collector header and
body straps to a roof or rack using a 1/4˝lag bolt and cap.
7
Cap 06919
Black, weather resistant polymer. Threads onto base to secure strap.
8
21/2” Hose
Clamp 02031
Stainless steel 21/2” hose clamp. Secures Rubber Couplers to barbed
fittings. Tighten using flat head or 5/16” socket driver.
9
Rubber Coupler
(3-1/2”) 02033
31/2” long, 23/8” inner diameter reinforced EPDM used to join the barbed
fittings on a VRV with those on the Pipe Adapter.
10
Rubber Coupler
(5”) 02035
5˝long X 2-3/8˝inner diameter reinforced EPDM used to join the
collectors to the barbed pipe adapters. Allows for flexibility between
collectors and hard piping.
11 Header Strap
(32”) 03431 Black, weather resistant braided polyester. Anchors top solar collector
header to cap and base.
12
Body Strap 03430
Black, weather resistant braided polyester. Anchors solar collector body
to cap and base. (150ft Roll)
13
Check Valve 02046
White, PVC 2˝female slip check valve prevents water from flowing
backward through the filter and backflushing debris into the pool when
the collectors drain.
Array Components
Components & Parts List

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Components & Parts List Cont’d
Item Kit P/N Purpose/Use Contents
14 Collector Pack 150
Plumbs and mounts a
collector. (One per
Collector)
15 System Pack 153
Terminates plumbing
and mounting a single
bank, adds a check
valve at plumbing (One
per System)
(1) CPVC end cap, (1) vacuum relief valve, (2)
CPVC female adapters, (7) tie-down caps, (7) tie-
down bases, (4) clamps, (2) 5˝couplers, (1) 32˝
header strap, (1) 2˝ check valve, (1) Owner’s
Manual
16 Add Bank Pack 154
Adds parts to
terminate plumbing
and mounting a bank
(One per added bank
of collectors)
(1) vacuum relief valve, (1) CPVC end cap, (2)
CPVC female adapters, (7) tie-down caps, (7) tie-
down bases, (6) clamps, (1) 3 1/2” coupler, (2) 5”
couplers, (1) 32” header strap
17 Split Pack 155
Allows for space
around an obstacle.
(one per row space
needed)
18 Collector
Repair Kit 162 Repairs leaks in collector tubes
19 Plumbing
Expansion Hose TBD
Allows movement of
plumbing in longer
pipe runs
SunSaver Kits Available

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Components & Parts List Cont’d
Alternate Vendor Components
Item Image Component Purpose/Use Suggested
Vendors
18 Isolation Valves
(2-way pool, gate, or
ball valves)
Enables isolation of solar (use for
winterization or troubleshooting purposes)
19
Manual Vertical
Solar Drain Valves
Can enable manual draining of a system
(use when a solar system is located below
pool level or to drain roof plumbing in
special circumstances)
20
Manual Collector
Drain Valves
Enables Manual Draining of a collector (use
in low point plumbing if trapped water
remains on shut down)
21
3 Way Diverter
Valve
Enables pool water to be directed to solar
or directly to the pool return (use in all
solar equipped systems)
22
Automated Solar
Diverter Actuator
Enables automatic movement of 3-way
diverter valve (use with pool automation
and pool controllers)
23
Pool Check Valve
Prevents water from flowing in a reverse
direction when unintended (use after the
pool filter and on the solar return line
plumbing)
24
Collector Substrate
Used as both a barrier and a support
structure. Use substrate on all tile roofs
and in cases where runners span more than
16”.
25
Metal/Wood
Runners
Use as a support and mounting structure.
Install under collectors and anchor to roof
or rack with proper penetrations.

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Legend for Figure 2
Standard Equipment
Pool Pump
Filter
Check Valve
Diverter Valve
Isolation Valve
Isolation/Check Valve
Solar Drain Valves (2)
Vacuum Relief Valve
5” Hose Connection
3.5” Couplers
SunSaver®Collectors
End Cap
1
2
3
4
5
6
7
8
9
10
11
12
Automation Equipment
Automation Controller
Pool Temperature Sensor
Solar Temperature Sensor
Actuator for Diverter Valve
Auxiliary Equipment
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14
15
16
17
Optional Pool Equipment (Aux)
Back Up Heater
Not Shown:
Chlorinator
Additional Pumps
A
Figure 3
Diverter Valve
Schematic
1
2
3
5
6
7
9
8
11
12
13
15
14
4 & 16
17
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Either Tee Upward or Opposing
Corner Acceptable
Manual Isolaon Valve or
Check Valve Permied
Oponal
Figure 2 | Example SunSaver®System
The typical SunSaver® solar pool system consists of a combination of FAFCO®-sourced parts and standard equipment. The above figure and the component list below
depicts standard equipment components and shows the proper placement of all components. All FAFCO®SunSaver®pool systems should have the standard equip-
ment listed and shown.
System Overview

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Refer to the Array Components List on the previous pages for further details about the array components in the above figure
*Header Straps must be installed directly perpendicular to header and fix-mounted panel must be wrapped twice, with mounting cleat roughly 2” away from header
** Number of Body Straps determined by local wind load requirements
System Overview Cont’d
Figure 4 | Typical SunSaver®Array Layout Components
The typical SunSaver® solar pool system consists of a combination of FAFCO®-sourced parts and standard equipment. The above figure and the component list below
depicts common Array Layout Components and shows the proper placement of all components.
Legend for Figure 4
Array Layout Components
SunSaver®Collector (4ft wide)
SunSaver®Collector (2ft wide) (not shown)
Vacuum Relief Valve
End Cap
Pipe Adapter
Base
Cap
1
2
3
4
5
6
7
Hose Clamp
3-1/2” Hose Coupler
5” Hose Coupler
Header Straps*
Body Straps**
Substrate (not shown)
8
9
10
11
12
13
1
3
4
5
6&7
8
9
10
11*
12**
51-1/2” ± 1/4”
Centered Between Collector Gaps
at Operang Temperature

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As with any installation, safety is the first priority. The department of Occupational Safety and Health Admin-
istration (OSHA) requires certain personal safety precautions to be taken by all solar installers who walk, carry or
lift anything and especially when doing so up ladders and on the top of structures. Please familiarize yourself with
and implement the appropriate safety regulations before beginning any installation.
Quick Tips
• Suggested order of Roof Equipment installation: Collectors → Plumbing →Penetrations → Secure Plumbing
• Suggested order of Thermal System Plumbing installation: Supply and Return Lines → Pool Equipment
• The most resilient method of installing collectors requires that mid-collector anchors are measured out prior to
collector placement.
Alternatively, collector banks can be plumbed and circulated with pool water to ensure that mid-collector an-
chors are centered at operating temperature.
• Collectors must be installed with a minimum of a 2”/12” slope to maintain uniform flow and properly drain.
• Avoid walking on collectors wherever possible. Walking on collectors can cause damage and the potential for
leaking.
• When laying out collectors for installation, check for miscellaneous hardware or other items which could get
caught between the roof and the collectors that may strike and damage a collector.
• Systems installed on tile or standing seam roofs must be installed on a substrate barrier so that the collectors
are supported and protected from abrasion.
Alternatively, if wood or metal runners are installed to support the collectors, runners must be spaced no
more than 16”. Installations with runners do not require substrate to be installed under collectors.
• It is typically acceptable to use Schedule 40 PVC for system plumbing. In extreme conditions, CPVC plumbing
may be more applicable. See Table 4 in Appendix C.
• Flush out all pipes before connecting them to collectors in order to clear any chips which may have become
trapped in the plumbing.
• Systems with local lows in the plumbing should have a way of manually draining the line for easy winterization.
• Banks should be mounted so that the centermost collector is fixed. This may be done by double wrapping ei-
ther side of the upper header on the panel to Fix-Mount (see Figure 11). Doing so will limit bank movement
when pressure and temperature cycling takes place through normal operation.
• Banks can be installed with 3.5” couplers but need 5” couplers when connecting to plumbing supply and re-
turn lines.
• Mid-bank obstacles should maintain a clearance of 2” from collectors. See Appendix C for specific exceptions.
• Plumbing Offsets may be used to allow for lateral movement between SunSaver® banks and system plumbing as
shown in Phase I—Site Preparations & Planning Figures 6 and 7 and in Figures 19 through 22 of Appendix C.
• An expansion joint can be used to allow for both bank and plumbing movement. To use an offset for absorbing
bank movement, use the offset distance for obstacle avoidance in Table 3 of Appendix C to size the offset dis-
tance needed for the selected offset method (Tables 5 through 7 of Appendix C).
• It is acceptable to utilize industry standard practices not mentioned in this text to accommodate for plumbing
expansion and contraction.
• Movement in a straight run of plumbing more than 10ft in length should have a means of accommodating ther-
mal expansion and contraction.
• All Flexible PVC plumbing must be thoroughly protected from UV exposure by means of paint, wrapping or
equivalent means of preference.
Safety & Disclaimer

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PHASE I —Site Preparations & Planning
Planning a roof layout for necessary penetrations, mounting, and plumbing will make installation easier and pro-
mote a cleaner looking system. While SunSaver®systems install quickly, there are some special considerations to
keep in mind. The following sections of Phase I will help prepare you for a simple and successful install.
SunSaver®collectors should only be installed in portrait
orientation so that water will flow directly up the roof.
Banks are to have a maximum of 15 collectors
plumbed together in a row. All panel banks must be
plumbed in parallel flow path.
Since the expansion or contraction of a bank is de-
pendent on temperature, the preferred method of in-
stallation is to measure out the placement of the collec-
tors on a roof and position the penetrations by measur-
ing them and using a chalk line and tape measure to
locate all penetrations.
When using the pre-measured method, the spacing
should be set at 51-1/2”. The last mounting points in
the bank should be placed with an extra 2-4” of clear-
ance for excessive bank movement.
A secondary means of placing mid-bank penetrations
would be to install the mounting hardware by centering
everything at operation temperatures. See System De-
tail Installation in Phase II for specifics about cen-
tering penetrations at temperature.
In addition, collectors may need to be spaced out to
allow for mid-bank obstacles or changes in roof shape.
In most cases, the banks will need to have additional
spacing added so that the bank can be plumbed
around the obstacle. Gaps can be filled by connecting
PVC runs to Pipe Adapters and Couplers as depicted in
Figure 10.
Collector Layout
Spacing Collectors and
Penetrations
Collectors will also grow or shrink along the length of
the collector. Be sure to mount collectors so that
there is at least 2” of clearance from the bottom
headers to any obstacles below the bank.
It is not acceptable to install two stacked banks
so that the upper header of the lower bank and
the lower header of the upper bank are touching
and tied together. Instead, mount each bank indi-
vidually with adequate clearance.
Many roofs have vents and other obstacles protrud-
ing from the surface. It is common for collectors to be
installed with spaces in the bank. Roof obstacles pose
an additional factor to consider during planning the
roof layout. Collector movement is a normal occur-
rence with pressure and temperature fluctuations in
the system. If not properly placed, collectors can col-
lide into penetrations or roof obstacles and cause
damage to the collectors. To limit unnecessary dam-
age and likely voiding of FAFCO®’s collector warranty,
banks must be installed so that proper clearance is
allowed on either side of an obstacle. See Table 3 in
Appendix C for more specifics about proper obstacle
clearance upon installation. A best practice rule of
thumb to use for proper obstacle clearance is 2” but
less clearance may be acceptable depending in the
size of the bank installed as indicated in Table 3. In
most cases, banks will need to be adapted to PVC by
using couplers and pipe adapters to plumb to PVC
Pipe (Figure 10). This method allows for any gap size
seen in common practice.

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PHASE I —Site Preparations & Planning Cont’d
Roof-based plumbing involves two parts, the plumbing
connections between several individual collectors and
the supply and return lines that connect each row of
collectors to the pool plumbing.
Row-to-piping connections may only be installed in the
End Supply/Return or Reverse/Return styles. To en-
sure each collector receives adequate flow, install End
Supply/Return rows with a maximum of 10 SunSaver®
Collectors and Reverse/Return rows with a maximum
of 15.
Row-to-piping connections must be designed in such a
way that all bottom headers can drain when the sys-
tem is turned off. Ensuring that horizontal runs of pipe
have a level or slightly downward slope will allow prop-
er drainage to the pool. If plumbing does not drain
down when the system is turned off due to local en-
trapment, manual drain valves should be installed for
simple winterization or a winterization contract should
be maintained.
NOTE: See your warranty policy for specifics of cov-
erage policies.
Systems with more than one row require means of flow
balancing. A common high point return (seen in Figure
5)will achieve proper collector flow uniformity. Plumb-
ing the return line with a high point will enable a com-
parable backpressure on the return line of each bank
and therefore match collector flow throughout the ar-
ray.
Unlike FAFCO®CoolPV®Systems, SunSaver®Systems
do not utilize an individual high-point-return line.
When installing both SunSaver®and CoolPV®Systems,
plumbing must conform with the schematics in Figure
8 to ensure the system is properly balanced and drains
as intended.
It is acceptable to omit a high point return and use
balancing valves to achieve adequate bank flows. In
most cases, a high point return style plumbing will be
the easiest to achieve, but in circumstances where a
high point plumbing routing is not a good option, bal-
ancing valves can be used instead. For specifics of in-
stalling a SunSaver®system with balancing valves, re-
fer to Appendix C.
Plumbing Layout
Figure 5 | High Point Return Line
Multi-Bank SunSaver®Pool Systems utilize a common high point re-
turn line. This enables each bank to have proportional feed and re-
turn line backpressures which limits the water to favor the path of
least resistance. Without a common high point return line, the low-
est bank will see too much flow and the top won’t see enough, re-
sulting in poor performance of the top bank. Notice A) is an exam-
ple of a Multi-Bank Reverse Return and B) is a Multi-Bank Same End
Return.
A) Multi-Bank Reverse Return
    
      

 
 


 
  

    
      

  
 
 

B) Multi-Bank Same End Return

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When routing plumbing, consideration should be tak-
en to ensure it will be properly guided so that it
moves as intended. Common practice is to strap
plumbing lines with a galvanized plumbing strap an-
chored by 1 or 2 fasteners. These types of mounting
allow for movement perpendicular to the direction of
the strap. If plumbing is strapped parallel to the di-
rection of movement without a means of accommo-
dating it in the line, thermal effects can tear out the
strapping and cause costly damages. Refer to local
plumbing codes for proper mounting practices of
PVC.
There are multiple methods of accommodating both
bank and plumbing movement. Figure 7 below ex-
plains some ways of accommodating both bank and
plumbing movement. More details are available in
Appendix C for reference.
The use of a plumbing offset is a largely common
means of enabling axial growth and shrinkage in long-
er runs of plumbing. By offsetting the plumbing with
90° fittings and strapping it in accordance with Fig-
ure 18 and Table 5 in Appendix C,proper movement
can be allowed to take place without cracking fittings,
tearing out mounting points, and restricting the
movement of a solar system.
Note that this is not the only means of properly ac-
commodating for plumbing and bank movement. In-
dustry standard methods are also acceptable. For
more details on proper plumbing mounting and move-
ment, consult a certified pluming specialist and local
plumbing codes.
Figure 7 | Row Plumbing Movement
A bank of 5 collectors from the Fixed Collector can move up to 2.5” from normal temperature fluctuations (1.2” in a single direction). Two
Plumbing Expansion Hoses are advised to accommodate this movement when the plumbing is strapped as shown. Refer to Table 6 in
Appendix C for recommended Plumbing Expansion Hose lengths. In this case, the movement in the bank corresponds to 1.2” which can also be
transposed to an equivalent of 40ft PVC pipe (Table 5). Additionally, there is a 10ft line of PVC. Adding the two provides 50ft of equivalent
length, requiring a 16” expansion hose (sourced from Table 6). Since the plumbing can be mounted as Fixed or Guide supports, an offset may
also be useful to absorb some or all of the movement in the above figure. Refer to Appendix C for more variations of Row Plumbing Movement.
Note: It’s also acceptable to use another industry standard method to accommodate for thermal movement. Variations of
these recommendations can be used as long as sufficient movement for a standard temperature range of 80°F is allowed.
PHASE I —Site Preparations & Planning Cont’d
Fix-Mounted Collector Bank Moves up to 5X
(±1/4”) = 2.5”
Collector 0 Collector 1 Collector 2 Collector 3 Collector 4 Collector 5
Flexible
Expansion
Joint
(advised)
Fixed
Support
Fix-Mounted Collector
Collector 0 Collector 1 Collector 2 Collector 3 Collector 4 Collector 5
~4ft ~4ft
~10ft
~16in
Hose
Guide
Support
Figure 6 | Row Plumbing Movement
A straight line of plumbing can move up 1” for a length of 25ft. Plumbing Expansion Joints are advised to accommodate this movement. An industry standard method, such
as an offset should be used so that the line can move as needed. Refer to Table 5 for Regular PVC Joint Offset lengths and offset type for a length of pipe. See Appendix C
for alternate methods of accommodating for plumbing movement.
Regular PVC Pipe
(2X) Straight
Line Plumbing
Fixed
Support
Guide
Supports
Fixed
Support
(~4ft)
Length of Pipe

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Horizontal runs of PVC pipe must be supported every
four feet and all vertical runs of PVC pipe must be sup-
ported every ten feet. Vertical lines take the water from
the ground up to the roof and are usually on the walls
of the main structure. Pipe supports on the roof should
be sealed according to an industry standard method.
Pipe supports should be secured and properly guide
thermal movement (see figures in Appendix C). Proper
plumbing installation enables the plumbing to move
minimally but accommodates movement of solar collec-
tor banks.
Both Floating Guide and Fixed Guide connections
should be incorporated in conjunction with an indus-
try standard method to absorb plumbing movement as
referenced in Figure 20 of Appendix C.
Prime consideration should be given to system drain-
age and appearance when running pipe from the pool
pump to the collectors and back. Best practice allows
system drainage with a slight and consistent down-
ward slope in all horizontal runs.
Supporting PVC Pipe
Roof plumbing should schedule 40 PVC conforming
to ASTM D1785 or equivalent standard.
PVC is generally an acceptable material for plumbing
FAFCO®solar thermal systems. In most cases, an oper-
ating solar thermal system does not exceed the temper-
ature rating of white PVC. Unless it can be shown that
black PVC withstands equivalent temperature and pres-
sure specifications of white PVC by providing documen-
tation that it conforms to ASTM D1785 or an equivalent
standard, it should not be used for solar plumbing.
Due to the poor UV resistant properties of PVC, it
should be painted upon completion of the installation.
Plumbing Materials
PHASE I —Site Preparations & Planning Cont’d
Hybrid System Layouts
SunSaver®collectors are compatible with most sys-
tems, including FAFCO®’s CoolPV® panels.
The best way to install a hybrid SunSaver®/CoolPV®
system is to prioritize placement and plumbing to the
CoolPV®panels and then to install SunSaver®collec-
tors on the remaining roof space. SunSaver®collec-
tors are less sensitive to location, which will have a
lesser impact on performance than a CoolPV®panel.
To see how a split Hybrid system should be plumbed,
refer to Figure 8.
Roof Penetrations
All mounting penetrations must be installed as de-
scribed in Phase I Site Preparation and Planning.
All roof penetrations should be sealed with an in-
dustry standard method.
In many jurisdictions, painting the plumbing is re-
quired by code.
Instances occur where a system will be pressurized
while at elevated temperatures. CPVC offers a much
higher operating temperature and should be con-
sidered for use on the supply and return lines, es-
pecially for installations of more than two stories
and those likely to see water temperatures above
140°F such as sections of plumbing where water
can be entrapped at an elevated temperature. (see
Table 4, Appendix C).
Figure 8| Hybrid CoolPV®and SunSaver®Plumbing Schematic

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16
PHASE II —System Installation Detail
Mounting Collectors
Be mindful when handling SunSaver®collectors.
Rough handling can cause unnecessary body damage
which will likely result in premature failure or leak-
ing.
CAUTION: Before installing collectors, check roof
and racking for protruding hardware that may dam-
age the collectors.
Collectors should be installed insert to insert with the
coupler pushed all the way up to the edge of the col-
lector body and insert dam.
SunSaver®collectors can increase up to 2” in length as
they heat up on hot summer days. Ensure there is
roughly 2” of extra space at the end of the collector for
growth with temperature.
Because of this movement, it’s advisable to put some
material under the couplers to prevent any unwanted
abrasion to the roof or mounting structures.
When installing the collectors, pay careful attention to
install the couplers all the way up against the collector
insert and to position the hose clamps as indicated in
Figure 9 below. This greatly reduces the need for col-
lector adjustments later on.
Initial collector alignment can be done while installing the Coupler connec-
tions. Note that the collector Hose Clamps must be installed all the way up
against the Insert Barb and positioned to clamp over the Insert Landing. The
Hose Clamps must be positioned as best to the depicted. Inadequate place-
ment of these components can lead to excessive expansion of the Collector
bank and cause damage and leaking. Dimensions depicted are typical and may
vary slightly. Placement should be checked when the system is up and run-
ning, by making sure all couplers haven’t moved more than 1/8”.
Figure 9 | Collector Coupling
9/16”
1-3/16”
Coupler is
Flush Against
Collector
Coupler
Hose
Clamp
Insert
Barb
Insert
Landing
Note: It is crucial that the collector couplers and
hose clamps are installed properly. If improperly
positioned, the hose clamps and couplers can
move and the entire bank of collectors can expand
severely under pressure, causing the collector body
to collide with roof-mounted obstacles.
When installing mounting hardware, it is best practice
to use the premeasured method mentioned in Collector
Layout of PHASE I—Site Preparations and Planning.
It can be easier to place penetrations after all plumb-
ing is installed. Therefore, it is also acceptable to use
the below alternate method of placing mid-bank pene-
trations.
Note: This method can only be used if the pool can
be circulated to the solar system such that the col-
lectors have an approximate surface temperature
of 70-90°F. The surface of the collectors can be
measured with an irradiance meter or similar sur-
face temperature measuring device. If needed, ad-
just the flow rates to the solar system to achieve
an acceptable reading for the procedure.
Note: Use caution if employing this method and do
not perform in high wind conditions since collec-
tors aren’t fully mounted.
Follow these steps to mount collectors for this method:
1. Lay collectors in desired locations and plumb
them together
2. Determine the centermost collector (or a collector
which the bank needs to move about) and fix-
mount it by double wrapping the upper headers
(described in Figure 11) and securing the strap
roughly 2” directly above the header.
3. Mount upper headers of remaining collectors
4. Route and connect all plumbing to the system
5. Circulate pool water (70-90°F) through the solar
system
6. Let pool water circulate through the collectors un-
til all air is purged out
7. While the solar system is running, mount hard-
ware by centering penetrations between each col-
lector
8. Once all mounting has been completed, turn the
system off and ensure that the bank doesn’t move
into mounting hardware. If it does, address as
needed.

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17
Obstacle Avoidance
PHASE II —System Installation Detail Cont’d
Connect Supply & Return Lines
5” EPDM hose couplers are used to make a semi flexi-
ble connection from a SunSaver®bank to Schedule 40,
2” PVC piping. Below is the best order to follow for con-
necting the supply and return lines:
1. Check that all supply lines are connected to the lowest
end of their collector row and that the upper ends feed
to a common high point in the system. (as in Figure
5).
2. Connect 5” couplers on upper and lower inserts of
all collector corners for supply and return plumb-
ing. Be sure to install hose clamps as depicted in
Figure 9.
3. Route supply line to the bottom header of each row
4. Route the return line to the upper header of each
row.
5. If there are straight pipe runs in the plumbing ex-
ceeding 15ft without an offset, there must be either
a plumbing expansion kit installed or an industry
standard method to accommodate for any expan-
sion and contraction (see Plumbing Layout and Ap-
pendix C for details).
6. Both supply and return line plumbing must be
mounted so that it is allowed to move an equivalent
of 1/2” for every collector between it and the Fix
Mounted collector in the bank. If there are multiple
collectors, it may be advisable to install an Expan-
sion joint immediately in the plumbing so that
when the bank moves with temperature, the plumb-
ing will be able to absorb the movement immediate-
ly. Refer to Plumbing Layout and Appendix C.
CAUTION: Overtightening Hose Clamps will deform
connectors and accelerate compression set in de-
formed EPDM hose and will lead to leaking. Torque
all hose clamps to 35-42 in-lbs.
Figure 10 | Adding Space to a Row
In order to accommodate for obstacles in a row, collectors may need
to be spaced out by adapting the couplers to PVC.
Collectors
PVC Pipe
Pipe
Adapter
Hose
Clamp Coupler
Since the collectors are made of a polymer that sees
large temperature swings, there can be a lot of natural
movement in an array as well as all plumbing. If sim-
ple practices are not adhered to, this natural move-
ment can cause damage to solar collectors, plumbing
and roof penetrations.
As seen in Phase I, Plumbing Layout and Appendix C,
SunSaver®banks move both laterally and longitudi-
nally along the roof. It’s often best to mount the mid-
point of the bank so that the movement is divided
evenly to both sides of the bank. This can be done by
double wrapping a header strap around the fixed col-
lector on both upper headers and installing the Caps/
Bases up to 2” away from the header (see Figure 11).
Use a means of fix-mounting this collector which best
fits the practices of installation company. The plumb-
ing end of the bank will move simply from the move-
ment of the bank which will then translate to the
plumbing. Since there can be movement translated to
the plumbing, it’s crucial to plumb the banks so that
this movement can either be absorbed in the coupler
or absorbed in the plumbing. To accommodate for
movement in the banks, all plumbing must be coupled
to the bank with a 5” coupler and if there is a long run
of plumbing going directly to the bank, accommoda-
tions for thermal expansion must be utilized. Refer to
the Figures 16 and 20 in Appendix C.
Collectors may need to be spaced out to allow for mid-
bank obstacles or changes in roof shape. In most cas-
es, the banks will need to have additional spacing
added so that the bank can be plumbed around the
Figure 11|The Fix-Mounted Collector
On the Fix-Mounted Collector, the upper headers should be double
wrapped on both sides to keep the Collector as an inflection point of
bank movement. A means of limiting bank movement should be used
which best fits the practices of the installation company.
Double
Wrap
(Fixed Points)

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18
The Diverter Valve is the “on switch” for the solar sys-
tem. It should be set to both allow and prevent flow
into the solar system (shown in Figure 12) and installs
in the pool plumbing as detailed in Figures 26-29 of
Appendix E.
An actuator will be needed when automating a solar
system. Follow the procedure specified by the manu-
facturer of your actuator. By positioning the valve as in
Figure 12, the actuator cams can be left 180° apart, as
provided by the manufacturer.
See Appendix E for detailed alternate Diverter Valve
placements and types.
The 2877 Jandy Pro Series non-positive diverter valve,
or equivalent is recommended along with a pool auto-
mation system of choice.
When installed as specified by FAFCO® Inc. no mod-
ification of diverter valves or actuators is neces-
sary.
Diverter Valve
Install a Vacuum Relief Valve (VRV) by plumbing up
with a “TEE” fitting on the return line from the highest
bank. See the Collector to VRV section of Figure 4for
an assembly schematic. Only one is necessary for each
roof pitch in a typical system and should be installed
on the highest bank. Note that it’s permissible to install
the VRV so that it functions as an end cap for the op-
VRV & End Caps
PHASE II —System Installation Detail Cont’d
obstacle. Gaps can be filled by connecting PVC runs to
Pipe Adapters and Couplers as depicted in Figure 10.
Regardless of the type of gap needed in a bank, the
procedure will be as following:
1. Begin by laying the collectors as intended in the
layout. Start with the collector(s) which pose the
most limitations on mounting. As each collector is
placed, ensure there is proper obstacle avoidance
by allowing a 2” clearance.
2. If less than 2” clearance is available, consult Table
3in Appendix C to determine an absolute mini-
mum gap size needed for the obstacle.
Note: Narrow collectors (2ft wide) can be
useful on roofs where there are multiple obsta-
cles to avoid and standard size collectors don’t
fit.
3. Once all collectors have been positioned with
clearance, finish plumbing the collectors as de-
scribed in Phase I —Mounting Collectors and Con-
nect Supply and Return Lines.
4. After turning on the system, ensure the banks
have not moved too close to obstacles and address
as needed.
5. Once fitment is verified, finish mounting by adding
mid-bank roof penetrations by centering with the
system running.
6. The collectors may then be strapped down with
collector body straps. Do so by starting on one
side of the bank, tightening down the strap with
the Cap to the Base and work through the bank
one strap at a time. Note: Collector straps
should be installed with a mild amount of ten-
sion so as to not be exceptionally loose. If nec-
essary, let slack into the series and repeat. Do
not install strapping around lower headers.
Panels need to move up and down the roof with
temperature fluctuations.
Diverter Valves should be set to allow two flow options. One design option is
depicted. Alternate methods are outlined in Appendix E.
A) System Off, Leaving all three paths open B) System On, closing the path on
the To Pool side. (In some cases, plumbing the Diverter with a Neutral flow
position (depicted) can allow partial flow to the solar and overheat the pool.
Consult your local install department or FAFCO®for further details.)
Figure 12 | Diverter Flow
BA
posing corner of the bank and that there are fewer
parts involved if doing so this way. The primary rea-
son for “Teeing” up the VRV is that it will likely be less
prone to failure from sediment buildup during opera-
tion. Systems with rows on multiple roofs require an
additional VRV for each pitch.
Install End Caps to seal headers opposite the supply
and return connections by assembling a 3.5” couplers
and hose clamps onto the inserts which aren’t being
used for plumbing. All Hose Clamps should be tight-
ened by a torque wrench to 35-42 in-lbs.

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19
Pool Equipment Tie In
Once the plumbing is completed and ready to tie in
to the solar array on the roof, the pluming is ready to
be connected to the pool equipment.
Note: It is critical to manually flush any debris
out of the lines before connecting the solar array
and the pool equipment.
Follow these steps for flushing the lines:
1. Ensure all plumbing is connected except the cou-
plings to the solar array and the final lines at the
pool equipment.
2. Manually plug the solar lines at the pool equip-
ment with a rag or loose pipe cap (or at the low
point in the plumbing).
3. Using a garden hose, fill both supply and return
lines with water at the high points in the system.
4. Allow the water to release from the lines and
purge the debris from the plumbing system.
5. Repeat if necessary.
Note: This procedure can also be performed by
plumbing everything except the final connection
to the collector banks and using the pool pump to
circulate water to the roof.
Once lines are properly purged of any chips or other
debris, both the solar array and the pool equipment
can be connected. See Figure 2 and Appendix E for a
complete description of all necessary components at
the pool equipment.
Automating the solar pool heating system is not re-
quired, though is highly recommended by FAFCO®. Sys-
tems that are automated will be able to run when ambi-
ent conditions support pool heating. If the pool system
is not automated, the solar system may be mistakenly
left on when there is not adequate solar energy to heat
the pool and could cause the pool to lose heat, thus
countering the purpose of the solar heating system. In
addition, a manual diverter valve can be left on and
overheat the pool or cause a stagnation effect when the
pump is turned off. Caution: Stagnated solar systems
can trap water at scalding temperatures and result
in severe burns if not treated properly.
Electrically operated solar controllers are available from
a variety of manufacturers. When installing an automat-
ed system be sure to read and follow the directions for
the controls equipment to ensure their proper operation.
It is highly recommended that all solar systems be in-
stalled in conjunction with a pool automation system for
optimum system performance.
Thermal System Automation
Pool Plumbing
The solar thermal system is installed after the pump
and filter but before additional pool equipment. (Figure
2).
Alternatively, if pool equipment is specifically la-
beled by manufacturer as to be installed before the solar
equipment, then the it may be before the solar system.
Such equipment may include intellichems, and Ultraviolet
cleaning systems.
The first component after the filter is a check valve. Al-
ways leave room for check valves to be cut out and re-
placed. The use of pool swing or spring check valves,
such as the 7305 Jandy Pro Series, are recommended.
Next, the diverter valve and PVC tees are installed.
Install an isolation valve, such as a PVC ball valve or
equivalent, on the piping going to the solar. Install a
second isolation valve on the return line. If desired, a
check valve can be used on the return line in place of the
isolation valve. These components are always installed
before any back up pool heaters or chlorinators.
PHASE II —System Installation Detail Cont’d
CAUTION: If the isolation valve on the return line
were closed while the system was running, damage
to the system would result from over-
pressurization.
Always be sure to turn both valves when isolating the
solar system from the main pool equipment.
Manual solar drain valves are only recommended to
be placed on plumbing lines which don’t drain when
equipment is turned off. The primary purpose of man-
ual drain valves is to provide easy draining access for
service and winterization.
Drain valves should be installed in an accessible
location at the lowest elevation possible and MUST
adhere to the placement shown in Figures 2 and
13.
Flush out all pipes before they are connected to the
thermal system as specified in Pool Equipment Tie In.
Once plumbing is connected, ensure all lines exposed
to the sun are properly protected from UV exposure.
Most common practice is to thoroughly paint all
plumbing.
Note: If using Flexible PVC lines as a means of ab-
sorbing Thermal Movement, use multiple coats of
paint or cover the segments with a UV burier such
as a braded sheathing to keep the segment thor-
oughly protected from excessive UV exposure.

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20
Test that the thermal system will hold under normal oper-
ating pressure without leaking (no greater than 30 psi
with the system below 100°F).
CAUTION: Over-pressurizing SunSaver®collectors will
void the warranty.
1. Open the isolation valve and direct the diverter
valve to allow flow into the thermal loop.
2. Turn on pool pump.
3. Allow the system to run, checking all pipes, con-
nections, and collectors for signs of leaking.
4. If no leaks appear then the system is ready for op-
eration. If leaks do occur, address the issue and
repeat the test procedure.
Pressure & Leak Check
When automating a system it is critical that tempera-
ture sensors be placed in appropriate positions. Please
refer to the manufacturer’s installation manual of your
chosen controller.
Pool Temperature Sensor
A sensor is used to ensure that the controller is alerted
when the pool temperature is too low.
Solar Temperature Sensor
By taking measurements of the roof, or of conditions
similar to it, the controller can compare the solar tem-
perature to the current pool temperature. This infor-
mation allows the system to achieve the desired, final
pool temperature.
Placement of Sensors
PHASE III —Commissioning
The diverter valve is critical to the function of the ther-
mal system. Ensure it functions properly.
1. Check that the actuator repositions the valve when
directed.
2. Check that the set positions direct flow as ex-
pected.
Diverter Valve
To ensure optimum performance, it is highly recom-
mended to automate all solar thermal systems with an
automation package of choice. There are many auto-
mation packages which are available from pool suppli-
ers such as Pentair, Jandy, and Hayward. It is recom-
mended by FAFCO®to source from a supplier of your
preference.
A Solar Pool Automation Kit should include a mini-
mum of the following:
1. A Diverter Valve Actuator (180° or 90°)
2. An in-plumbing Pool Temperature Sensor
3. An ambient Solar Temperature Sensor
4. A Programmable Automation Controller
It is common to program the controller so that the so-
lar system will run if roof temperatures are 10°F or
greater above the pool temperature and to bypass the
solar if the roof is 4°F or less above pool temperature.
For further system automation, see instructions from
the Manufacturer of the equipment being used.
System Automation
Ensure the full solar pool system is operational. Refer
to the associated installation manuals as necessary.
Once everything is functioning as intended for normal
operation, fill out the Commissioning & Warranty Regis-
tration documents located in Appendix B.
Once the documents are complete, use FAFCO®’s
online portal to obtain a system warranty registration
number. Provide the homeowner a copy of the Com-
missioning Documents and a FAFCO®Owner’s Manual
for their records.
Commissioning Documents