Related Manuals for FAFCO Connected Tube CT Series
Summary of Contents for FAFCO Connected Tube CT Series
- Page 1 ® S o l a r P o o l H e a t i n g S y s t e m s I N S T A L L A T I O N M A N U A L FOR USE WITH SWIMMING POOLS TO HARNESS THE ENERGY OF THE SUN...
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Page 2: Table Of Contents
® ® Installation Manual Table of Contents System Overview Theory of Operation Specifications, Certifications & Listings Components & Parts List System Overview Safety & Disclaimer Quick Tips PHASE I — Site Preparations & Planning Panel Layout Spacing Panels and Penetrations Splitting Panels Around Roof Vents Plumbing Layout Supporting PVC Pipe... - Page 3 ® ® Installation Manual Table of Contents PHASE IV — Routine Maintenance Winterization Spring Startup Pool Maintenance Panel Repairs Closing Checklist Appendix A — Commissioning Checksheet Appendix B — Pump Sizing Pump Sizing Calculation Tables Example Pump Sizing Calculation Example Manufacturer’s Pump Curves Appendix C —...
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Page 4: System Overview
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. -
Page 5: Specifications, Certifications & Listings
5.1gal Fluid Capacity (gal) 6.8L 7.9L 9.1L 10.25L 14.4L 17.0L 19.3L 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 Panel Thermal Specifications* Thermal Energy Output 1800 Btu / (ft2-day) System Operating Pressure (<100 °F) At Bottom Header... -
Page 6: Components & Parts List
® Components & Parts List Panel Part Numbers Item Image Name Description 4ft Connected Tube CT Panels. These 4ft wide Panels are Connected available in four different lengths, 12ft (45 sq.ft.), 10ft (38 sq.ft.) Tube CT 20412 (12ft) and 8ft (30 sq.ft.) and 6ft (23 sq.ft.) (4ftx 12ft) 20410 (10ft) (4ft x 10 ft) - Page 7 ® Components & Parts List Array Components Item Image Name Description Black, weather resistant CPVC, 2” PVC pipe size, barbed. Seals Vacuum Relief system when pressurized and allows Panels to drain when the Valve (VRV) system is off. Adapts to Solar Panel using Panel Coupler. Black, weather resistant CPVC, 2˝...
- Page 8 ® Components & Parts List Cont’d Panel Kits Available Item P/N Purpose/Use Contents (2) header anchors, (4) coupler clamps, (2) panel couplers, (7) strap anchors Plumbs and mounts a Panel Kit 10201 Panel. (One per Panel) Terminates plumbing (1) vacuum relief valve, (1) CPVC end cap, (7) strap anchors, (3) and mounting a single pipe adapters, (2) panel couplers, (4) coupler clamps, (1) 150ft roll bank, adds a check...
- Page 9 ® Components & Parts List Cont’d Alternate Vendor Components Item Image Component Purpose/Use Suggested Vendors Isolation Valves Enables isolation of solar (use for (2-way pool, gate, or winterization or troubleshooting purposes) ball valves) Can enable manual draining of a system (use when a solar system is located below Manual Vertical pool level or to drain roof plumbing in...
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Page 10: System Overview
The typical 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 pool systems should have the standard equipment listed and shown. - Page 11 Centered Between Panel Gaps at Operating Temperature Figure 4 | Typical Panel Array Layout Components The typical 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.
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Page 12: Safety & Disclaimer
® Safety & Disclaimer 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. - Page 13 • It is generally not advised to install FAFCO Separated Tube ST panels with roof vents protruding from between the tubes, but if necessary it can be permitted as long as the vent is away from the header pipes by at least 12”...
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Page 14: Phase I - Site Preparations & Planning
Vents II for specifics about centering penetrations at temper- ature. It is generally not advised to install FAFCO Separated In addition, Panels may need to be spaced out to allow Tube ST panels with roof vents protruding from be- for mid-bank obstacles or changes in roof shape. In... -
Page 15: Plumbing Layout
ble backpressure on the return line of each bank and therefore match Panel flow throughout the array. B) Multi-Bank Same End Return Unlike FAFCO CoolPV Systems, Connected Tube CT ® ® Figure 5 | High Point Return Line and Separated Tube ST Systems do not utilize an indi- vidual high-point-return line. - Page 16 ® PHASE I — Site Preparations & Planning Cont’d Figure 6 | Row Plumbing Movement A straight line of plumbing can move up 1” for a length of 20ft. 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.
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Page 17: Supporting Pvc Pipe
Hybrid System Layouts Plumbing Materials Panels are compatible with most systems, including Roof plumbing should be schedule 40 PVC conform- ing to ASTM D1785 or equivalent standard. FAFCO ’s CoolPV panels. ® ® PVC is generally an acceptable material for plumbing... -
Page 18: Phase Ii - System Installation Detail
® PHASE II — System Installation Detail Mounting Panels Note: It is crucial that the Panel couplers and cou- Be mindful when handling Panels. Rough handling pler clamps are installed properly. If improperly can cause unnecessary body damage which will like- positioned, the coupler clamps and couplers can ly result in premature failure or leaking. -
Page 19: Connect Supply & Return Lines
Pipe Adapters and Couplers as depicted in Figure 10. exceeding 10ft without an offset, there must be For simplicity, the FAFCO Spacer Kit (PN 10203) con- either a plumbing expansion kit installed or an tains added components to space out a panel row industry standard method to accommodate for around roof obstacles. -
Page 20: Vrv & End Caps
“TEE” fitting on the return line from the highest position (depicted) can allow partial flow to the solar and overheat the pool. bank. See the Panel to VRV section of Figure 4 for an Consult your local install department or FAFCO ® for further details.) -
Page 21: Pool Equipment Tie In
Automating the solar pool heating system is not re- the pool equipment. quired, though is highly recommended by FAFCO . Sys- ® tems that are automated will be able to run when ambi- Pool Plumbing ent conditions support pool heating. -
Page 22: Phase Iii - Commissioning
Pentair, Jandy, and Hayward. It is recom- 2. Check that the set positions direct flow as ex- mended by FAFCO to source from a supplier of your ® pected. -
Page 23: Phase Iv - Routine Maintenance
® PHASE IV — Routine Maintenance Winterization Spring Startup Spring Startup for solar Panels is essentially the oppo- Note: Panels are not warrantied against freeze dam- site order of winterizing but also includes checking for age. leaks and any damage which could have occurred during CT Panels must be completely drained and isolated be- the winter season. - Page 24 ® PHASE IV: Routine Maintenance VRV: Winter: Removed Summer: Installed Body Straps 4-12” Above Lower Header End Caps: Drain Valves: Winter: Removed Winter: “Open” Summer: Installed Summer: “Closed” 2 Automation: Winter: “OFF” Summer: “ON” Isolation Valves: Winter: “OFF” Summer: “ON” Figure 13| Solar System Maintenance Figure 13 depicts the components to decommission, remove or reinstall during sys- tem Winterization, Summerization or when performing other routine maintenance.
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Page 25: Pool Maintenance
Refer to the product warranty policy backwashing, or pool vacuuming (see Figure 13 for for information regarding other damages. component locations): In order to repair a tube leak, use only a FAFCO Pan- ® 1. Turn the pump and solar system “OFF” (1 & 2) el Repair Kit (PN 161). -
Page 26: Closing Checklist
NEW COMBINED RELEASE IN- CLUDING: Updated for narrow panels, new 3/2023 couplers, coupler clamps, strap clamps, header anchors and com- bined CT and ST manual. FAFCO , Inc. ® 435 Otterson Drive Chico, CA 95928 Phone: (530) 332-2100 FAX: (530) 332-2109... -
Page 27: Appendix A - Commissioning Checksheet
® APPENDIX A — Commissioning Commissioning Check Sheet System Owner ____________________________ ____ Phone ________________________ Installation Address ___________________________________________________________________ Installed By ______________________________ _______ Install Date: ___/___/___ Phone ___ _______________ Install Company ______________________________ _______ if applicable General Installation Practices The centermost Panel in a bank is “Fix-Mounted” so that the rest of the bank moves about the centermost Panel Each Panel is mounted and spaced to allow for thermal expansion and contraction Strap Anchors are centered between Panels when system is running at operating tempera-... -
Page 28: Appendix B - Pump Sizing
® APPENDIX B — Pump Sizing Pump Sizing Calculation Tables Table 1: Head Loss Calculation Table for 2" PVC Fittings Equivalent Pipe Length Fitting Used Head Loss of Fitting (ft) Quantity Used Totals Box I Box A Box E (A*E) 45°... -
Page 29: Example Pump Sizing Calculation
® APPENDIX B — Pump Sizing Example Pump Sizing Calculation Example Table 1: Head Loss Calculation Table for 2" PVC Fittings Equivalent Pipe Length Fitting Used Head Loss of Fitting (ft) Quantity Used Totals Box I Box A Box E (A*E) 45°... -
Page 30: Example Manufacturer's Pump Curves
® APPENDIX B — Pump Sizing Example Manufacturer’s Pump Curves 85FT Recommended Pump Speed Curve 85 FT Recommended Setting... -
Page 31: Appendix C - Reference Tables & Figures
® APPENDIX C — Reference Tables & Figures Bank Movement Clearances Table 3 | Obstacle Clearance Under normal movement of a bank, each Panel will have an incremental Obstacle Clearances Needed growth and contraction factor of 1/4” for each Panel away from the fix- # of Panels from Permissible Obstacle mounted Panel in the bank. -
Page 32: Various Plumbing Configurations And High Point Return
® APPENDIX C — Reference Tables & Figures Various Plumbing Configurations & High Point Return SPLIT FEED / SPLIT RETURN ... -
Page 33: Plumbing With Balancing Valves, No High Point Return
® APPENDIX C — Reference Tables & Figures Plumbing with Balancing Valves, No High Point Return Figure 17 | Balancing Valve Technique Multi-Bank Pool Systems utilize balancing valves on the supply line enabling each bank to have proportional feed which limits the water to favor the path of least resistance. -
Page 34: Plumbing Movement
® APPENDIX C — Reference Tables & Figures Plumbing Movement Direction of Guide Supports Plumbing Only Movement Figure 18 | PVC Plumbing Offset Right: A common industry standard for a plumbing offset (see Table 5 below for offset distance L). This offset can be oriented vertically (as shown) or hori- zontally to accommodate thermal movement in the direc- tion of the plumbing. - Page 35 ® APPENDIX C — Reference Tables & Figures Plumbing Movement Figure 20 | Flexible PVC Offset Fixed *Flexible PVC Hose Support (~4ft) (2X) Straight Line Plumbing Guide Fixed Supports Support Length of Pipe Expansion Dimensions Chart Flexible PVC Line Offsets T=80°F Most Installations Most Installations, with Bank Movement Uncommon Installations...
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Page 36: Bank And Plumbing Movement
® APPENDIX C — Reference Tables & Figures Bank and Plumbing Movement DIAGRAM LEGEND: Bank Moves up to 5X Plumbing Fix-Mounted Panel* Guide Fixed Points (±1/4”) = 2.5” Expansion Support Joint Plumbing Fixed Expansion Support Joint ~10ft L/4 = 7” min ~4ft Bank Moves up to 5X Fix-Mounted Panel*... -
Page 37: Appendix D - Roof Mounting Details
® APPENDIX D — Roof Mounting Details Connected Tube CT Panels on Composition Roofs Attachment to truss COMPOSITION HEADER ANCHORS SHINGLES OVER UNDERLAYMENT AND SHEATHING BASE SHEATHING COMPOSITION SHINGLE 5/16” LAG BOLT SOLAR PANEL TRUSS OR RAFTER Attachment to blocking BODY STRAP STRAP ANCHOR BASE... -
Page 38: Separated Tube St Panels On Composition Roofs
® APPENDIX D — Roof Mounting Details Separated Tube ST Panels on Composition Roofs Attachment to truss COMPOSITION HEADER ANCHORS SHINGLES OVER UNDERLAYMENT AND SHEATHING BASE SHEATHING COMPOSITION SHINGLE 5/16” LAG BOLT SOLAR PANEL TRUSS OR ST STRIP FACING UP RAFTER Attachment to blocking BODY STRAP... -
Page 39: Connected Tube Ct Panels On Tile And Standing Seam Roofs
If a system must be installed without adequate substrate and runners, it’s best advised to install the FAFCO Separated Tube ST Panel rather than the FAFCO Connected Tube CT panel. Mounting hardware must be installed on a runner and the runner must be mounted into the sheathing of the roof with the same number of penetrations. -
Page 40: Separated Tube St Panels On Tile And Standing Seam Roofs
If a system must be installed without adequate substrate and runners, it’s best advised to install the FAFCO Separated Tube ST Panel rather than the FAFCO Separated Tube ST panel. Mounting hardware must be installed on a runner and the runner must be mounted into the sheathing of the roof with the same number of penetrations. -
Page 41: Panels On Tile And Standing Seam Roofs, Tile Stand Off And Tile Clip Method
® APPENDIX D — Roof Mounting Details Panels on Tile and Standing Seam Roofs Figure 27A | Tile Stand Off Method Figure 27B | Tile Clip Method The figures depict examples of mounting hardware on Flat Tile roofs. Substrate is required to support and protect the Panels from abrasion but may be substituted by a roof rack with support from runners not exceeding 16”... -
Page 42: Header Clamp Mounting On Tile Roofs
® APPENDIX D — Roof Mounting Details Header Clamp Mounting on Tile Roofs Figure 28 | Header Clamp Mounting The figures depict examples of mounting a Header Clamp on tile roofs. When mounting on a tile roof, the panel must be installed so that the ST Strip is facing downward toward the tile. -
Page 43: Panels Wood Rack Mounted
If a system must be installed further below the pool surface level, it’s best advised to install the FAFCO Separated Tube ST Panel rather than the FAFCO Connected Tube CT panel. -
Page 44: Panels, Metal Rack Mounted
If a system must be installed further below the pool surface level, it’s best advised to install the FAFCO Separated Tube ST rather than the FAFCO Connected Tube CT panel. -
Page 45: Appendix E - Alternate Methods Of Compliance
® APPENDIX E — Alternate Methods of Compliance Acceptable Installation of Valves Figure 31| Diverter Valve on Supply, Isolation on Return The below figures depict alternate types and locations of the diverter valve and check/isolation valve. Non-draining configurations should be manually drained for winter, self-draining systems do not require draining for winterization. - Page 46 ® APPENDIX E — Alternate Methods of Compliance Acceptable Installation of Valves Figure 32| Diverter Valve on Supply, Check Valve on Return The below figures depict alternate types and locations of the diverter valve and check/isolation valve. Non-draining configurations should be manually drained for winter, self-draining systems do not require draining for winterization.
- Page 47 ® APPENDIX E — Alternate Methods of Compliance Acceptable Installation of Valves Figure 33| Diverter Valve on Return, Isolation on Return The below figures depict alternate types and locations of the diverter valve and check/isolation valve. Non-draining configurations should be manually drained for winter, self-draining systems do not require draining for winterization.
- Page 48 ® APPENDIX E — Alternate Methods of Compliance Acceptable Installation of Valves Figure 34| Diverter Valve on Return, Check Valve on Return The below figures depict alternate types and locations of the diverter valve and check/isolation valve. Non-draining configurations should be manually drained for winter, self-draining systems do not require draining for winterization.