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Connect Supply & Return Lines
Panel Couplers (PN 10196) are used to make a semi
flexible connection from a Panel bank to Schedule 40,
2" PVC piping. Below is the best order to follow for
connecting the supply and return lines:
1. Check that all supply lines are connected to the low-
est end of their Panel row and that the upper ends
feed to a common high point in the system. (as in
Figure 5).
2. Connect panel couplers (PN 10196) on upper and
lower inserts of all Panel corners for supply and
return plumbing. Be sure to install Coupler
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
exceeding 10ft without an offset, there must be
either a plumbing expansion kit installed or an
industry standard method to accommodate for
any expansion and contraction (see Plumbing
Layout and Appendix C for details).
6. Both supply and return line plumbing must be
mounted so that it is allowed to move an equiva-
lent of 1/2" for every Panel between it and the Fix
Mounted Panel in the bank. If there are multiple
Panels, it may be advisable to install an expansion
joint immediately in the plumbing so that when
the bank moves with temperature, the plumbing
will be able to absorb the movement immediately.
Refer to Plumbing Layout and Appendix C.
CAUTION: Overtightening Hose Clamps can deform
couplers and lead to leaks.
Obstacle Avoidance
Since the Panels are made of a polymer that experi-
ence large temperature swings, there can be a lot of
natural movement in an array as well as all plumbing.
If simple practices are not adhered to, this natural
movement can cause damage to solar Panels, plumb-
ing and roof penetrations.
As seen in Phase I, Plumbing Layout and Appendix C,
Panel banks move both laterally and longitudinally
along the roof. It's often best to mount the midpoint of
the bank so that the movement is divided evenly to
both sides of the bank. This can be done by use of
fixed point header anchors on the fixed Panel of both
PHASE II — System Installation Detail Cont'd
upper headers (see Figure 11). Use a means of fix-
mounting this Panel which best fits the practices of
the installation company. The movement of the bank
will translate to the plumbing. It is crucial to plumb
the banks so that this movement can either be ab-
sorbed in the coupler or absorbed in the plumbing. To
accommodate for movement in the banks, all plumb-
ing must be coupled to the bank with a panel coupler
(PN 10196) and if there is a long run of plumbing go-
ing directly to the bank, accommodations for thermal
expansion must be utilized. Refer to the Figures 16
and 20 in Appendix C.
Panels 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
obstacle. Gaps can be filled by connecting PVC runs to
Pipe Adapters and Couplers as depicted in Figure 10.
For simplicity, the FAFCO Spacer Kit (PN 10203) con-
tains added components to space out a panel row
around roof obstacles.
Regardless of the type of gap needed in a bank, the
procedure will be as following:
1. Begin by laying the Panels as intended in the lay-
out. Start with the Panel(s) which pose the most
limitations on mounting. As each Panel is placed,
ensure there is proper obstacle avoidance by al-
lowing a 2" clearance.
2. If less than a 2" clearance is available, consult Ta-
ble 3 in Appendix C to determine an absolute min-
imum gap size needed for the obstacle.
Pipe
Adapter
Panels
Figure 10 | Adding Space to a Row
In order to accommodate for obstacles in a row, Panels may need to
be spaced out by adapting the couplers to PVC (Split Pack, PN 155)
Coupler
Coupler
Clamp
PVC Pipe
®
19
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