1. DL manuals
  2. FAFCO
  3. Water Heater
  4. 500 Series
  5. Installation Manual

FAFCO 500 Series Installation Manual

Manual is about: Closed Loop Solar Hot Water System

Summary of 500 Series

  • Page 1

    500 series closed loop solar hot water system installation manual made in the u.S.A. Note: this manual provides a detailed, step-by-step procedure for installing the solar water-heating system. The directions should be followed properly, and only recommended components and hardware should be used. T...

  • Page 2: Table Of Contents

    Introduction ..........................................1 safety ..................................................2 code and certification requirements..3 parts list..............................................4 optional kits ........................................5 tools required....................

  • Page 3: Warning

    2 dangerous heights solar collector(s) are often installed on the roof of a building. Unless you’re familiar with working on roofs and have the proper ladders and safety equipment for such work, you should hire someone with the necessary experience to do the installation. Failure to observe safe pra...

  • Page 4

    Code requirements refer to the local authority having jurisdiction, such as the local building department or utility, to ensure all installation work meets applicable require- ments. Use the fafco permit package, available for download at www.Fafco.Com, to submit to the local authority having jurisd...

  • Page 5: Parts List

    4 power supply 18* 28* 24* 4* roof kit: two 2’ x 12’ collectors pn 08881 or three 2’ x 8’ collectors pn 08911 mounting bases pn 06918 13 13 2 mounting caps pn 06919 roof jack pn 08211 roof sealant, 10 oz. Tube pn 08229 mounting strap, 40’ roll, pn 08907 1 1 20 collet clips pn 08819 roof sensor pn 08...

  • Page 6: Parts List (Continued)

    5 parts list (continued) tools required channel lock pliers two or more ladders wire cutters cordless power drill wire strippers hammer 3/4” & 1-1/4” paddle bit caulking gun 1/4” drill bit tape measure 5/16” & 7/16” socket driver stud finder #2 & #3 phillips screw driver level 3/4” masonry bit (for ...

  • Page 7: Overview

    6 there are three basic solar water heating system configurations: • dual-tank gas or electric • single-tank electric • single-tank with on-demand gas heater components vary based on configuration. Refer to the schematics on the following pages for further details. Two 2’ x 12’ solar collectors dual...

  • Page 8: Overview (Continued)

    7 overview (continued) dual tank system solar-heated water in the solar storage tank preheats the water to the electric or gas water heater. A solar storage tank connection kit (pn 730-1) is available from your supplier to connect the solar storage tank to the electric or gas water heater. Temperatu...

  • Page 9: Overview (Continued)

    8 overview (continued) single tank system solar-heated water is stored directly in an electric water heater with a single active upper element, rather than a separate storage tank. Electric water heater: an electric water heater can be either be one that is manufactured with only one element, or an ...

  • Page 10: Overview (Continued)

    9 solar-heated water in the solar storage tank preheats the water to the gas on-demand water heater. A solar storage tank connection kit (pn 730-1) is available from your supplier to connect the solar storage tank to the gas on-demand water heater. For an on-demand water heater to properly work with...

  • Page 11: Overview (Continued)

    10 overview (continued) dc solar loop pump (fafco p/n 08795) dc potable loop pump (fafco p/n 08795) dc differential temperature controller (fafco p/n 08783) solar loop outlet solar loop inlet potable loop outlet potable loop inlet ground, pv, & sensor wire terminal block temperature display button b...

  • Page 12: Overview (Continued)

    11 retaining ring expansion reservoir uv resistant air vent/pressure relief valve, 1 psi mounting holes fluid inlet or outlet fluid inlet or outlet uv resistant bladder vent cap internal rubber air bladder black uv resistant reservoir function: installed at the highest point of the system, it serves...

  • Page 13: Overview (Continued)

    12 plastic tubing • provided fafco tubing is weather resistant. • pex (cross-linked polyethylene) tubing approved for use with push fittings may be used, but must not be exposed to sunlight. • plastic tubing will expand and contract at different temperatures. • tubing should be supported at a minimu...

  • Page 14: Installation Checklist

    13 installation checklist 10-step installation process 1: site selection and planning 2: roof mounting 3: tank plumbing 4: icm installation 5: tubing & sensor installation—below roof 6: tubing & sensor installation—roof 7: system fill 8: system start-up 9: system operation 10: troubleshooting.

  • Page 15

    14 1: site selection and planning it’s important to choose the best roof loca- tion to install the solar collectors, based on the considerations below: roof direction for homes in the northern hemisphere, the best installation site is a roof facing true south. (see figure 4.) if a south-facing roof ...

  • Page 16: 2: Roof Mounting

    15 sheets are available from a fafco distributor or local home improvement store. Tile a tile roof installation kit (trik) should be used on tile roofs. Trik is available from your supplier. The kit includes specialized tile roof mounting hardware, substrate, and complete installation instructions. ...

  • Page 17

    16 2: roof mounting (continued) step 3: choose mounting location and layout collectors must be installed vertically, side-by-side, allowing at least 10 inches above the top headers for mounting of the reservoir and upper roof jack. Place the collectors, reservoir, and upper roof jack in chosen locat...

  • Page 18

    Step 2: shut off water supply step 1: turn off water heater note: install a new water heater at this point if the existing water heater will not be used. Follow the water heater manufacturer’s installation instructions. A drip pan with a drain line to the outside of the building is required whenever...

  • Page 19

    18 step 1: disconnect water heater piping 3: tank plumbing—single tank disconnect the water heater hoses. Replace if needed. Check that the water heater has dielectric nipples. Step 2: connect temperature control valve apply thread sealant and connect temperature control valve to the water heater po...

  • Page 20

    19 note: a solar storage tank add-on kit can be used for this installation configuration. This kit is available through your distributor. The tank is plumbed as shown. 3: tank plumbing—dual tank step 1: re-direct water supply re-direct the cold water supply line from the water heater cold inlet, to ...

  • Page 21: 4: Icm Installation

    20 4: icm installation step 1: mounting icm the integrated circulation module (icm) is mounted directly onto the water heater or solar storage tank sheet metal outer skin. Remove the icm cover and place the module against the water heater in a convenient location about 3” down from the top. Using th...

  • Page 22

    21 5: tubing & sensor installation—below roof (continued) step 2: connect lower roof jack tubing to icm step 3: pull upper roof jack tubing place tape over the end of the remaining tubing and push up through the left ceiling hole. Push the end of the 50’ roll of roof sensor wire up through the 1/4” ...

  • Page 23: 8: System Start-Up

    22 6: tubing & sensor installation—roof (continued) step 2: upper roof jack connection at the upper roof jack, cut off tubing and install elbow fitting. Lubricate the cut off tubing with water or silicon and insert 3” into reservoir rubber grommet. Cut tubing to length and connect to elbow fitting. ...

  • Page 24

    23 8: system start-up (continued) step 2: attach power cord before icm power cord attachment using the toggle switches on the top of the circuit board, set the solar switch to off and the max water temp switch to 120 °f. Route the power/ground cord into the icm next to the lower left flexible hose. ...

  • Page 25: 9: System Operation

    24 9: system operation the control component of your fafco solar water heating system features state-of-the-art microprocessor technology and many flexible features to maxi- mize the effectiveness and utility of your solar water heating system, with special emphasis on “user friendliness” and reliab...

  • Page 26: 10: Troubleshooting

    25 10: troubleshooting the solar water heating system is designed to operate trouble-free for many years. Use the table below to troubleshoot unexpected problems. 1) confirm that the system is not activating: • place your hand on the icm. You should feel a slight vibration and hear a slight hum. Cau...

  • Page 27: Specifications

    26 specifications pressure drop vs. Flow ( one collector ) pressure drop ( feet of w ater ) flow rate pressure drop ( psi ) 1 0 0 0 1 2 0.4 two 2’ x 12’ solar collectors roof mounting space: 7.5’ x 9’ (three collectors) three 2’ x 8’ solar collectors 1. Material: black uv resistant copolymer 2. Coll...

  • Page 28: Required Labels

    27 required labels.

  • Page 29: Optional Kits Instructions

    28 optional kits instructions pv panel kit ......................................29 collector add-on kit .........................33 coaxial adapter kit ............................34 tile roof installation kit (trik) .........36.

  • Page 30: Parts List

    29 once the pv panel kit has been installed and connected to the solar hot water system controller, the solar system will and operate on pv power, whenever sufficient pv power is available. The pv panel kit includes the required hardware for the panel to be installed in either a flush mount or tilt ...

  • Page 31: Pv Panel Kit

    30 step 2: layout angle mounts step 1: choose location step 3: affix angle mounts step 4: mount pv panel asphalt composition roof installation the two angle mounts are designed for the lag screws to be affixed into two roof trusses on 24- inch centers. Locate two trusses, place angles parallel to ea...

  • Page 32: Tile Roof Installation

    31 step 5: run pv panel wire into attic step 6: run 50’ pv wire step 7: connect pv wiring to icm step 2: mark upper angle mount location step 1: choose roof location step 3: drill mounting holes in angle step 4: drill mounting holes in tiles run pv panel wires alongside roof sensor wire under roof j...

  • Page 33: Pv Panel Kit

    32 step 5: seal and secure angle step 6: place lower angle mount step 8: secure pv panel to angles step 7: secure lower angle mount step 9: connect pv wire to panel step 10: connect pv wire to icm tile roof installation (continued) place a nickel size daub of roof seal- ant at each hole. Replace ang...

  • Page 34: Overview

    33 collector add-on kits are available for three 8-foot collectors or two 12-foot collectors. Each add-on kit contains parts and hardware to add an additional 48 square feet of solar collector area. Note: the system is designed for a maximum of two add-on kits, which will provide a maximum solar col...

  • Page 35: Overview

    34 the coaxial adapter conversion kit allows the solar tank drainport to feed and return filtered solar storage tank water to the icm. The adapter kit also retains the drain bibb for tank flushing or draining. The coaxial adapter conversion kit eliminates the brass tee fitting and filter screen atop...

  • Page 36

    35 coaxial adapter conversion kit apply thread seal- ant to the remaining reducer and install in cross. Install check valve, right side up, with arrow toward tee. Apply thread sealant and insert 1/2” nipple into check valve and tighten. Step 5: install reducer step 6: connect the 6’ hose to icm step...

  • Page 37: Overview

    36 tile roof installation kit (trik) overview note: use an additional trik for each collector add- on kit. All necessary materials are provided in the kit, except for weather resistant 1/4” lag screws for each tile clip, as these will vary in length depending on the tile shape. Also, two #14 x 2-1/2...

  • Page 38: Step-By-Step Installation

    37 tile roof installation kit (trik) step 1: attach bases to channels step-by-step installation step 2: determine layout step 3: snap chalk line step 4: remove tiles and drill holes step 5: attach tile clips step 6: attach channels a. Place upper header channel against the lip of the second tile row...

  • Page 39: Step-By-Step Installation

    38 step 8: mount collectors step 7: lay corrugated sheet step 9: mount expansion reservoir lay collectors on substrate with top headers hanging over substrate. Install and adjust header straps so that top headers remain hanging over and touch- ing the end of the sheet. Install the body straps. When ...

  • Page 40

    Visit www.Fafco.Com for current technical bulletins and other updates 435 otterson drive, chico, ca 95928-8207 • 800.994.7652 pn 08913a • 10/10