1. DL manuals
  2. FAFCO
  3. Water Heater
  4. Drainback 200 Series
  5. Installation Manual

FAFCO Drainback 200 Series Installation Manual

Manual is about: Solar Hot Water System

Summary of Drainback 200 Series

  • Page 1

    200 series drainback 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. Thi...

  • 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 en- sure all installation work meets applicable requirements. All installation work should be performed by a properly licensed contractor. Backup water heater and/or storage tank ...

  • Page 5: Parts List

    4 parts list power supply component image major components qty. Description / function qty. (2) 2’ x 12’ (pn 08842) or qty. (3) 2’ x 8’ (pn 08891) polymer unglazed solar collectors transfers solar energy to the heat transfer fluid. Controls the solar water heating system. Accommodates heat transfer ...

  • 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 • single-tank • single-tank with on-demand heater these systems can be used with either gas or electric water heaters. Components vary based on configura- tion. Refer to the schematics on the following pages for further d...

  • 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..

  • 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 electric water heater: an electric water heater can be either be one that is manufactured with only one element, or an electric water heater manufactured wit...

  • Page 10: Overview (Continued)

    9 solar-heated water in the solar storage tank preheats the water to the electric or 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 electric or gas on-demand water heater. For an on-demand water heat...

  • Page 11: Overview (Continued)

    10 overview (continued) on/auto/off switch function: controls the solar water heating system controller system overview (on-demand for gas or electric) component overview black uv resistant collector sheet solar collector black uv resistant collector header black uv resistant push fitting black uv r...

  • Page 12: Overview (Continued)

    11 circulation module mounting holes fluid inlet vented cap sightglass 10 gallon drainback tank system overview component overview overview (continued) self-cleaning filter function: cold water is pulled through the filter into the circulation module and returned at the drainport. 20 mesh filter scr...

  • 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: drainback tank installation 5: circulation module installation 6: controller installation 7: tubing & sensor installation 8: system start-up 9: system operation 10: troubleshoot...

  • 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 8’ or 12’ long, corrugated (wavy) sheet with ribs no more than 2˝ apart and 1˝ high, fiberglass or polycarbonate 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 suppli...

  • 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 6 inches above the top headers for mounting hardware. Place the collectors and upper roof jack in chosen location as shown. Roof jack installs black si...

  • Page 18

    17 step 6: install body straps apply roof sealant at lag screw location, 1” from collector edge, 4” down from the top header. Drive a lag screw through the base. Orient the slot for the strap horizontally and tighten lag screw. Lay the strap in the slot of the base and screw down the cap until tight...

  • Page 19

    Step 3: snap chalk line step 4: remove tiles and drill holes step 5: attach tile clips step 6: attach channels snap a vertical chalk line down the roof for aligning the channel ends. Each channel gets 3 tile clips for the 8-foot collectors; 2 clips for the 12-foot- ers. If working with curved tiles,...

  • Page 20

    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 21

    20 step 1: disconnect water heater piping 3: tank plumbing—single tank remove heater vent and vent cap from the water heater (gas only). Disconnect the water heater hoses. Replace if needed. Check that the water heater has dielectric nipples. Step 2: connect temperature control valve apply thread se...

  • Page 22

    21 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 23

    2) solar collector installation storage tank bypass label 3: tank plumbing—storage tank drain port adapter step 1: install brass cross apply thread sealant to the 3” nipple and install finger tight into one port of 3/4” brass cross. Install nipple and cross assembly into drain port at the bottom of ...

  • Page 24

    22 step 8: drive bottom screw step 6: drive top screw step 4: connect throttling valve step 7: level tank step 5: push tube back into tank step 3: locate the ceiling hole step 2: measure the location step 1: locate wall stud 4: drainback tank installation optional mounting: if a stud isn’t convenien...

  • Page 25

    23 step 6: install push fittings step 1: drive two mounting screws step 8: install tube to drainback tank step 4: connect to coaxial adapter step 7: ensure proper insertion step 5: connect to coaxial adapter step 3: connect flexible hoses step 2: remove protective covers 5: circulation module instal...

  • Page 26: (Continued)

    24 2) solar collector installation (continued) 5: tubing & sensor installation—below roof step 2: push tubing through right hole step 8: connect tubing to module step 10: connect to throttling valve step 9: push tubing through left hole step 7: slide on ceiling flange step 3: pull tubing through att...

  • Page 27

    2) solar collector installation 25 5: tubing & sensor installation—below roof (continued) step 12: pull wire into attic step 14: connect reducers step 18: secure roof sensor step 15: install tubing inserts step 13: tie sensor wire to tubing step 11: drill ceiling hole for roof sensor 6: tubing & sen...

  • Page 28: (Continued)

    26 2) solar collector installation (continued) 7) solar controller installation step 1: remove controller cover plate step 9: replace controller cover plate step 3: locate the tank sensor step 5: splice roof sensor wire step 7: insert roof sensor into t1 step 2: remove lower tank cover step 10: veri...

  • Page 29: 8: System Startup

    2) solar collector installation 8: system startup step 1: open hot water faucet step 3: open cold water inlet valve step 5: turn on water heater step 7: inpect for leaks step 2: open main water valve step 4: check plumbing for leaks step 6: fill drainback tank step 8: activate circulation module rem...

  • Page 30: 9: System Operation

    28 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 maximize the effectiveness and utility of your solar water heating system, with special emphasis on “user friendliness” and reliabil...

  • Page 31: 10: Troubleshooting

    29 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 32: Specifications

    30 collector, srcc model 2007030a : 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’ (basic kit with three collectors) three 2’ x 8’ solar collectors 2...

  • Page 33

    31.

  • Page 34

    Visit www.Fafco.Com for current technical bulletins and other updates 435 otterson drive, chico, ca 95928-8207 • 800.994.7652 pn 08941• 10/10