Solar panels leak water on the roof or at header manifolds when the pump is running.

Safety: Turn off the pump and relieve pressure before working on any solar plumbing. Use fall protection on the roof.

• Locate leak: Run the system briefly and visually identify the exact leak point at the Fafco panel header or coupler.
• Isolate solar loop: Close the solar supply and return valves and drain water from the panels via a low-point drain or by loosening a union.
• Inspect couplings: Remove the leaking Fafco rubber coupler or union between panels. Check for cracks, hardening, or missing O-rings.
• Replace seals: Install new Fafco header O-rings and rubber couplers as needed. Lubricate O-rings with a silicone-based lubricant.
• Check panel header: If the plastic header itself is cracked, the panel may need replacement or a manufacturer-approved repair kit.
• Refill and test: Reopen valves, restart the pump, and inspect for leaks under full pressure.