FAFCO CoolPV User manual

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Made in the U.S.A.
FAFCO®
FOR USE WITH SWIMMING POOLS
TO ENHANCE SOLAR ELECTRIC
(PV) PERFORMANCE
OWNER’S
MANUAL
Solar Energy Perfected

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Your CoolPV®System
What to Expect From Your CoolPV®System
Theory of Operation
System Specifications
Components of a Typical CoolPV System
What do the Various Components Do?
Before Calling Your Dealer For Service
Freeze Protecting Your System
System Start-up After Freezing Conditions
Commissioning and Warranty Registration
General Tips For Optimum Performance
Owner’s Manual
Table of Contents
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Figure 1
CoolPV®Panel Components
Each CoolPV®Panel consists of (left to
right) a PV Module, a FAFCO Inc. Thermal
Collector, and a support structure which
ensures thermal connection between the
Module and Collector.
“Diablo Solar installed our CoolPV®System so our south-facing roof
could be used to substantially reduce our electric bill while using the
same roof space to keep our pool warm”
Meaghann and JD Tenuta
System Owner’s
Chico, CA

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Your CoolPV®System
Your CoolPV®System represents the most advanced solar system to date.
CoolPV®maximizes the use of your roof by enhancing electrical output
while simultaneously heating your swimming pool.
As the third generation system based on a US Navy contract, CoolPV®combines
one of the world's largest leading manufacturer of solar photovoltaic modules and
provider of solar energy solutions with the highest performing American made so-
lar thermal collector. CoolPV®Panels are manufactured in Chico, California by
FAFCO®Inc. Founded in 1969, FAFCO®Inc. is the oldest and largest solar ther-
mal company in the United States.
What to Expect From Your CoolPV®System
1. Noticeable increase in your electrical performance.
2. Raise and maintain your pool's temperature 5 to 15°F over a period of several
days of good weather.
3. Eliminate or significantly reduce the cost of operating your fossil fuel pool
heater, but not necessarily replace it during the colder, less sunny months (a
pool cover will enhance #1 & 2 above).
4. Give you years of trouble-free service.
Theory of Operation
As Photovoltaic (PV) solar modules reach higher temperatures, such as those
common on a roof, they lose efficiency and produce less electricity. CoolPV®Pan-
els solve this issue by directly cooling the module. Each CoolPV®Panel attaches a
FAFCO Inc. Thermal Collector to the back face of the PV module. Water flows
through the hundreds of small diameter tubes constituting each Thermal Collec-
tor, taking heat from the module, increasing the electrical performance of
CoolPV®by up to 10% higher than uncooled modules.
CoolPV®then returns the heated water to the pool. This reduces, and often elimi-
nates, the need for a traditional pool heater, which further reduces household en-
ergy costs.
“The most notable feature of Fafco’s CoolPV®System was the ease
of installation. The roof installation of a CoolPV®Panel is virtually
identical to a regular PV Module”
Mike Powers
Diablo Solar Services
Martinez, CA

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System Specifications
System Overview
295W CoolPV®Panel Specifications (CS6K-295MS, PN: 09883) 1
Panel Area 17.6 ft2 (1.67 m2)
Panel Dimensions (HxWxD) 65 x 39 x 4.72in (1650 x 992 x 120 mm)
Weight 55.3 lbs (25.1 kg)
Roof load 3.2 psf (15.6 kg/m2)
Fluid Capacity 0.75 gal (2.8 L)
Fluid Connection Type FAFCO®Proprietary
Electrical Connection Type T4 series
1Electical Specifications are based on Canadian Solar Inc. UL1703/UL2703 Certification Ratings
Electrical Specifications2295W
Rated Electrical Output (Pmax) 295 Watts
Open Circuit Voltage (Voc) 39.5 V
Rated Voltage (Vmpp) 32.3 V
Short Circuit Current (Isc) 9.75 A
Rated Current (Impp) 9.14 A
Temperature Coefficient - Pmax -0.39 % / K
Temperature Coefficient - Voc -0.29 % / K
Temperature Coefficient - Isc 0.05 % / K
Electrical Efficiency 18.02 %
System Voltage Max 1000 VDC
Power Tolerance -0 / +5 Wp
Number of Cells/Type 60 / Mono-crystalline
NMOT 43±3 °C
2All performance data calculated at STC (Standard Test Conditions) 25 °C, 1000 W / m2, 1.5 AM
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Thermal Specifications3
System Operating Pressure (<100 °F) 20 psi (140 kPa)
Factory Test Pressure / Burst Pressure Per Collector 50 psi / 220 psi (350/1500 kpa)
Recommended Flow Rate Per Collector 1.5 gpm (5.7 lpm)
Delta T (at y intercept) 3.3 °F (1.8°C)
Operating Temperature Range (typical) 60-100 °F (15-38°C)
Stagnation Temperature 140 °F (58°C)
3All performance data calculated at STC (Standard Test Conditions) 25 °C, 1000 W / m2, 1.5 AM, Inlet Water of 20 °C
CoolPV®Panels have been certified to meet the following standards:
 ICC-SRCCTM OG-100 Solar Collector Standard (All Sections)
 ANSI/UL1703 Standard for Flat Plate PV Modules and Panels
Section 25: Bonding Path Resistance Test
Section 31: Fire Tests (Class A)
Section 41: Mechanical Load Tests
Note: CoolPV® Panels maintain a 50psf Design load rating per UL2703, when used with UniRac®
Solar Mount Racking Systems.

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Figure 2
Components of a Typical CoolPV®System
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What Do the Various Components Do?
1.The CoolPV®System
When used in pool heating applications CoolPV®provides enhanced performance by:
 Cooling the CoolPV®Panels to enhance electrical output.
 Returning the heated water to the pool, extending your swim season.
2. Solar Drain Valves
Spigot style valves ensure draining. Some systems may instead connect a hose to the sys-
tem’s lowest point, which can then be run through the downspout of your gutter for easy
ground access.
3.The Isolation Valves
A manually operated valve (3a) is installed in the supply line and allows you to isolate the
CoolPV®System from the filtration system. It is primarily used when backwashing the filter
or at any time it is desirable to isolate the system. A check valve (3b) is installed in the re-
turn line to allow isolation and prevent over-pressurizing your system.
4. Diverter Valve
Automatically controlled valve that diverts the pool or spa water to the thermal system.
5.Your Heater
It is only needed to give your pool a supplemental heat boost, or when weather or special
occasions demand higher pool temperatures.
6 & 7.Your Pump and Filter
For optimal performance a variable speed pump is preferred. Please contact your FAFCO
Inc. dealer for more information. Keeping your skimmer and pump baskets clean enhance
performance by ensuring the maximum flow of cooling water. When cleaning the filter the
solar system should be isolated, preventing debris from entering the system.
8. Check Valve
When the pump (6) shuts off, the CoolPV®System (1) will drain. A Check Valve prevents the
water in the panels from flowing backwards through the Filter (7) and backwashing.
9.Vacuum Relief Valve (VRV)
Seals the system under pressure while maintaining a vacuum to minimize pumping power
required. The VRV must be located at the highest point in the system.
10. End Caps
These seal the headers on the end Solar Collectors in the System.
11. Solar Automation Controller
The Solar Automation Controller regulates the system automatically. By reading sensors on
the roof and in the pool water, it determines the optimum times run the thermal portion of
your CoolPV system.

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Before Calling Your Dealer For Service
If The System Does Not Appear To Be Supplying Sufficient
Electrical Power:
Check for shading of the panels and consider seasonal or other explanations. If the issue remains
unresolved call your authorized FAFCO Inc. dealer.
If Your Concern Relates To The Heating Of Your Pool:
1. Has your filter been backwashed and are the skimmer and the pump basket clean?
2. Have you been refilling the pool with a lot of cold water lately?
3. Has the weather been marginal?
4. Have you been using your pool cover as instructed?
5. Are the panels operating "cool" to the touch on a sunny day?
If There Are No Initial Bubbles When Plumbing Turns On
Bubbles on start-up are caused because air in the system must be replaced by water from your
pool to cool your PV modules and heat your pool simultaneously. If no bubbles appear check the
following:
1. Ensure that the pump is running.
2. Check the isolation valve to make sure it is open.
3. Make sure the diverter valve is in the correct position.
Tiny Champagne Bubbles
If tiny champagne bubbles continue past the initial purging of the panels (3-5 minutes), this may
be an indication that the water circulation through the panels has been reduced. To ensure that
the system has proper flow check the following:
1. Has your filter been backwashed and are the skimmer and the pump baskets clean?
2. Check the isolation valve to make sure it is open.
3. Make sure the diverter valve is in the correct position.
If the bubbles continue with the solar turned off, check the piping leading to the pump for a suc-
tion side leak.
Some small bubbles may always be discharged into the pool due to the particular operating char-
acteristics of the individual system. They do not affect the operation of the system nor impair the
proper function of any other pool equipment.

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Freeze Protecting Your System
The installations most prone to freeze damage include systems that have panels below the pool
water level and systems installed in hard freeze locations. All systems, when shut down for the
winter, must be checked to ensure that they are completely drained.
It is suggested to set up a winterization and spring tune-up schedule with your FAFCO Inc.
Authorized Dealer. CoolPV®Systems are not warranted against freeze damage.
If you choose to winterize your system yourself, please follow the steps bellow:
1. Ensure the diverter valve is set to bypass the CoolPV®System.
2. Ensure that the pump and filter are not running.
For panels below pool level, item 7 must be done before proceeding to item 3.
3. Open manual drain valves.
4. Remove Vacuum Relief Valve
5. Remove end caps at the lowest panel.
6. Let the system drain completely.
7. Close the isolation valve.
8. Turn on the pool equipment, ensuring that the diverter valve is turned to the thermal off posi-
tion. Let the system run for at least 5 minutes while checking to make sure no water is com-
ing out of the end cap area of the panels.
It is suggested to set up a winterization and spring tune-up schedule with your FAFCO Inc.
Authorized Dealer. CoolPV®Systems are not warranted against freeze damage.
If you choose to start up the system yourself, please follow the steps bellow:
1. Ensure the diverter valve is set to bypass the CoolPV®System.
2. Ensure that the pump and filter are not running.
3. Make sure that the end caps and vacuum relief valve are installed and the clamps are proper-
ly tightened. End Caps can be tightened to no more than 10in-lbs.
4. Close manual drain valves.
5. Open the isolation valve.
6. Turn the diverter valve to allow flow through the thermal system. (You may have to first select
the “manual on” function of your controller)
7. Turn on the pump and filter.
System Start-up After Freezing Conditions

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Commissioning and Warranty Registration
System Installed By: _____________________________________ Install Date: ___/___/___
(Company)
FAFCO Installation Stickers Placed: (check boxes)
Thermal Supply
Thermal Return
Thermal Drain Valve
From Pool
To Pool
Thermal Supply Isolation Valve
Thermal Return Check Valve
This document is to be filled out by the lead solar installer during Installation and Final Commissioning of the CoolPV®Sys-
tem. Keep this form in a safe location and be sure to send a copy to FAFCO, Inc. within 30 days of system installation date
or system will not be eligible for installer incentive program credits.
FAFCO Assigned Warranty Registration Number: _____________________________________
Array Plumbing Method Pipe Used to Plumb System System Location
_____________________________________
(Authorized CoolPV Installer)
Date: ___/___/___
Roof Orientation (circle all that apply) N NE E SE S SW W NW
Home Owner: _____________________________________
(First and Last Name)
Phone: ________________________
(Primary)
Email: _________________________________
(For essential contact and warranty registration purposes)
Installation Address: ___________________________________________________________________
(House Number, Street, City, State, Zip Code, Country)
Sales Rep: ______________________________
(Dealer sales representative who sold system to customer)
Certification Labels Present: (check boxes)
OG-100, ICC-SRCC (top header pipe)
ANSI/UL1703, TUV Rheinland (top header pipe)
Grounding and Racking: (check boxes)
Reverse/Return
End Supply/Return CPVC
PVC 2nd Story
1st Story
Array Layout: (check boxes)
Sketched
A copy of the system layout has been: Attached
Panel stickers removed from face of module and included on the system layout.
Filter Pressure Readings
Thermal System OFF: _____ _____ ON: __ ______ Difference: ____ ____ ( )psi / ( )kPa
UniRac Pro Series Mid Clamps Used
All Panels Grounded All Racking Grounded
UniRac Solar Mount Racking System Used
All Mid Clamps Were Tightened and Torqued
All End Clamps Were Tightened and Torqued
All Panel Clamps Were Checked for Secure Fastening

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General Tips For Optimum Performance
1. PV modules perform best when clean. Consider washing your CoolPV®Panels periodically.
2. Pool covers help your pool retain heat, reduce water loss caused by evaporation, and provide a
safer environment when designed and installed properly.
3. The use of variable speed pumps is recommended to conserve energy.
4. Maintaining a high rate of water flow allows for rapid pool water turnover and proper regula-
tion of pool chemistry. This keeps your pool clean and clear while making the CoolPV®System
perform optimally.
5. In hotter summer months consider adjusting your automatic system to heat only during the
hottest part of the day. This will optimize system performance without over-heating your pool.
Whenever service is required for other components in your pool system please call your
dealer for service.
FAFCO, Inc.
435 Otterson Drive
Chico, CA 95928
Phone: [phone]
FAX: [phone]
P/N 09698
Rev: —
12/11/18