FAFCO roof solar water leaks

[donaldm823]

Installed ten 12ft FAFCO solar panels on my roof in 2012 but experiencing pin hole leaks annually. Does anyone know what could be the cause of recurring pin hole leaks as one of the panels springs a leak 1-2 times per year requiring a $65 service call. FAFCO dealer says the number of leaks is normal!!

Have had only 2 panels leaking at the header area which required whole panel replace under warranty. Most of the leaks are fixed by plugging under warranty but since recurring (not on the same panel) and bothersome plus the $65 service charge. My roof solar system is running 12 months of the year for 6-8 hr per day and drains down when pool pump turns off at the end of the day. Water chemistry is well within range as I sample myself. Also panels water flow controlled by pentair solar controller and I run the pool at 87F year round. The leaks generally occur in Mar April or Nov each year

 

[mas985]

If they are truly pin holes, I would suspect a material failure because there is not much else that will make a hole that small.

 

[setsailsoon]

Installed ten 12ft FAFCO solar panels on my roof in 2012 but experiencing pin hole leaks annually. Does anyone know what could be the cause of recurring pin hole leaks as one of the panels springs a leak 1-2 times per year requiring a $65 service call. FAFCO dealer says the number of leaks is normal!!

Have had only 2 panels leaking at the header area which required whole panel replace under warranty. Most of the leaks are fixed by plugging under warranty but since recurring (not on the same panel) and bothersome plus the $65 service charge. My roof solar system is running 12 months of the year for 6-8 hr per day and drains down when pool pump turns off at the end of the day. Water chemistry is well within range as I sample myself. Also panels water flow controlled by pentair solar controller and I run the pool at 87F year round. The leaks generally occur in Mar April or Nov each year

Donald,

Fafco panels have a 30 year warranty and free replacement for the first 10 years. Doesn't make sense that your dealer would be repairing them. Both types of failures are typically repaired later in life by cutting the individual tube and installing a special plug at the header on both ends or installing a #10 SS screw. Each time they repair you lose a little surface area. At 2 years I'd want a new panel for any type of failure. Something doesn't smell right here. My Aquatherm warranty isn't as good as yours (10 years). I've had them in for 4 and like you, I run them year round. No pinhole failures. Only one leaking PVC fitting a few days after installation (they didn't glue it).

I hope this helps.

Chris

 

[TollHouse]

Curious if you were able to solve / resolve the issue?
I have 18 FAFCO sungrabber rooftop panels installed in 2016. By 2018 I had several that had developed tiny pin hole leaks at the headers, so small that it’s quite hard to see the actual leak, but after running for several hours you will see all the water on the roof, down the gutters...
I spoke with FAFCO re: warranty service in 2019, and FAFCO offered me a 5 year prorated warranty, which meant at that time they offered that I could purchase new panels @ 50% of the 2016 price. I felt that wasn’t a fair warranty, & since these panels had failed so quickly it didn’t make sense to reinvest in the same panels. That was the only warranty service offered to me. I declined that offer.
I haven’t had luck finding anyone re: repair, so if I turn the panels on I just have to live w/ the leaks which isn’t great for several reasons....

 

[setsailsoon]

Toll,

If the leak is at the place where the tube enters the header I'd try to seal with glue or plug them if it was me. Most manufacturers have a plugging procedure in their instruction manual. Even though I've got gutters to catch any water I just wouldn't want to run with that much of a leak. I guess warranty terms have changed or your model is covered by different terms than the ones I looked at. Pertinent content is pasted below in red text. Full warranty document I referred to previously is attached.

Chris

"THIRTY-YEAR LIMITED PARTS OR REPLACEMENT WARRANTY. FAFCO warrants to the original end-user purchaser (“Buyer”) of a FAFCO CoolPVTM Solar Collector that the thermal Collector will be free from defects in materials and workmanship for a period of up to thirty (30) years from the completion of its initial installation when used under normal application and service conditions for approved thermal applications and installed in strict accordance with FAFCO’s installation instructions, subject to the terms, conditions, and limitations described below. If a thermal Collector fails to conform to this limited warranty during the first (10) year period of the limited warranty, then FAFCO will provide to the original Buyer the necessary replacement parts or at its option will replace the defective thermal Collector with a new thermal Collector of at least the same quality, within a reasonable time period. If a thermal Collector fails to conform to this limited warranty during the remaining (20) year period of the limited warranty, FAFCO will replace or, at its option, repair a thermal Collector that is defective in material or workmanship at a cost to the original Buyer of 50% of FAFCO’s then current published list price. Replacement parts and units will be subject to the same limited warranty and original term as the original part or unit and the warranty period is not extended beyond the original term in the event of a repair or replacement. All replaced parts and units will become the property of FAFCO. This limited warranty does not include the costs of installation, removal, transportation or any other related labor costs or costs resulting from the lack of operation of the thermal Collector, the costs of which are the sole responsibility of the Buyer. This limited warranty is not assignable and applies only to the original Buyer while at the location of original installation. This limited warranty terminates upon the first to occur of a change in ownership of the premises at which the thermal Collector was originally installed or the removal of the thermal Collector from its original location of installation. As noted above, this limited warranty does not cover the solar PV modules or any products or component parts other than the thermal Collectors."

 

[TollHouse]

Chris,
Thanks for the advice, I will order some of the plugs,
any advice on which glue/ adhesive product I should try?

With the tube leaks, it's relatively easy to find the leak, however the leaks at the header are so small it's quite difficult to locate the actual hole where the leak is occurring as its soooo small. It's a bummer these panels has so many leaks because it actually does a good job in summer months of raising temps 10+ degrees in our 40,000 gallon pool :-(
I am going to investigate a different manufacturer (Techno-solis?) as well to potentially replace these Leaky FAFCO Sungrabber panels.

Regards,
Chris

 

[setsailsoon]

There's a new adhesive on the market that is the same used by dentists to seal fillings. It is perfect for very small leaks like this. I've found it works extremely well on some plastics. Comes in a kit with a UV light that sets it so it stays as a thick liquid until sealed. Of course there's always the venerable JB Weld. I'd try something like that or call TS at Fafco.

Chris