FAFCO Drainback 200 Series Installation Manual

Drainback solar hot water system

Hide thumbs

Table Of Contents

Table of Contents

Quick Links

200 Series

Drainback

Solar Hot Water System

Installation Manual

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. This will ensure a trouble-free system that will

maintain the warranty while providing solar energy and savings.

Made in the U.S.A.

Table of Contents

Need help?

Do you have a question about the Drainback 200 Series and is the answer not in the manual?

Questions and answers

Summary of Contents for FAFCO Drainback 200 Series

Page 1: Installation Manual
Water-Heating System. The directions should be followed properly, and only recommended components and hardware should be used. This will ensure a trouble-free system that will maintain the warranty while providing solar energy and savings. Made in the U.S.A. FAFCO © 2010...
Page 2: Table Of Contents
Table of Contents Introduction .......... 1 5: Tubing & Sensor Installation - Below Roof ..... 20 Safety ..........2 6: Tubing & Sensor Code and Certification Requirements.. 3 Installation - On Roof ....21 Parts List..........4 7: System Fill ........22 Optional Kits ........
Page 3: Safety
F. Freeze tolerance limits are based upon an assumed set of environmental conditions. MSDS is available at www.fafco.com for information on disposal and First Aid. FAFCO system is overheat protected and has little metal in contact with fluid. It therefore does not promote deposits, corrosion, or degradation of fluid mixture.
Page 4: Code And Certification Requirements
Refer to the local authority having jurisdiction and incentive providers for certification requirements. FAFCO solar collectors and systems listed in Specifications, page 25, are certified by the Solar Rating and Certification Corporation (SRCC), a nationally recognized certification for solar water heating collectors and systems.
Page 5: Parts List
Parts list Major Components COMPONENT IMAGE QTY. DESCRIPTION / FUNCTION Solar collectors 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. Controller Controls the Solar Water Heating System.
Page 6: Optional Kits
Parts list (Continued) Information Kit Owner’s Manual - PN 08942 Cold Water Valve Position Label - PN 08371 Freeze Protection And Fluid Safety Label - PN 08904 Label attachment zip-ties - PN 08307 Parts NOT Provided Pipe Insulation, A.O. Smith Conservationist Water R-2.6 min, 3/4”...
Page 7: Overview
Overview 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 details. Two 2’...
Page 8 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) 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 with two elements with the bottom element disconnected.
Page 10 Overview (continued) SYSTEM OVERVIEW SINGLE TANK WITH ON-DEMAND HEATER (ON-DEMAND FOR GAS OR ELECTRIC) 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.
Page 11 Overview (continued) SYSTEM OVERVIEW COMPONENT OVERVIEW (ON-DEMAND FOR GAS OR ELECTRIC) Solar Collector Black UV Resistant Collector Header Black UV Resistant Collet Cover Black UV Resistant Push Fitting Black UV Resistant Collector Sheet Function: Absorbs the energy from the sun to heat the solar loop fluid. Push fittings allow for quick, leak-free tubing connections sealed with internal rubber o-ring.
Page 12 Overview (continued) SYSTEM OVERVIEW COMPONENT OVERVIEW Circulation Module Potable Loop Solar Loop Inlet Inlet Potable Loop Solar Loop Outlet Outlet Drainback Tank Fluid Inlet Vented Cap Fill 100% just above elbow Mounting Holes Sightglass 10 Gallon Drainback Tank Minimum operating level Fluid Outlet Self-Cleaning Filter...
Page 13 FAILURE TO PROPERLY CONNECT FITTINGS CAN RESULT IN LEAKS. Plastic Tubing Tube Installation • Provided FAFCO tubing is weather resistant. • A support liner and collet clip must be used on • PEX (Cross-Linked Polyethylene) tubing approved every tube fitting to prevent tube disengagement.
Page 14: Installation Checklist
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: TROUBLESHOOTING...
Page 15 1: Site Selection and Planning It’s important to choose the best roof loca- tion to install the solar collectors, based on the Distance From Water Heater considerations below: The solar collectors should be as close as possible to the water heater. The closer the collectors are to the Roof Direction water heater, the shorter the tubing run will be.
Page 16: 2: Roof Mounting
2˝ apart and 1˝ high, fiberglass or polycarbonate sheets are available from a FAFCO distributor or local For any roofing material not covered here, check with a roofing contractor for the best method to attach the solar home improvement store.
Page 17 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 side up, with hole located near the bottom edge of a shingle.
Page 18 2: Roof Mounting (Continued) 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 2: Roof Mounting (Continued) Step 3: Snap chalk line Step 4: Remove tiles and drill holes Snap a vertical chalk A. Start with the clips line down the roof for at the bottom chan- aligning the channel nel, remove the tile ends.
Page 20: 3: Tank Plumbing
3: Tank Plumbing - Single Tank 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 water storage tanks are located above living space.
Page 21 3: Tank Plumbing—Single Tank STEP 1: DISCONNECT WATER HEATER PIPING 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 sealant and connect temperature control valve to the water heater port labeled “H”...
Page 22 3: Tank Plumbing—Dual Tank 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. STEP 1: RE-DIRECT WATER SUPPLY Re-direct the cold water supply line from the water heater cold inlet, to the tee above the temperature control valve as shown.
Page 23 2) Solar Collector Installation 3: Tank Plumbing—Storage Tank Drain Port Adapter STEP 1: INSTALL BRASS CROSS STEP 2: INSTALL DRAIN BIBB Apply thread sealant Apply fresh thread seal- to the 3” nipple and ant to the water heater install finger tight into drain bibb and install into one port of 3/4”...
Page 24 4: Drainback Tank Installation STEP 1: LOCATE WALL STUD Locate a wall stud near the desired drainback tank mounting position. Mark the location. STEP 2: MEASURE THE LOCATION Hold the drainback tank in place near the mounting site. The top of the drainback tank should be between 6”–12” from the ceiling.
Page 25 5: Circulation Module Installation STEP 1: DRIVE TWO MOUNTING SCREWS Mark two hole locations 6-3/4” apart on the wall along the stud at least 4” off the floor. Check for level and drive two 5/16” x 1-5/8” lag screws with a 7/16” socket, leaving about a 1/4“ gap to the wall. STEP 2: REMOVE PROTECTIVE COVERS Set the circulation module onto the mounting bolts.
Page 26 2) Solar Collector Installation 6: Tubing & Sensor Installation (continued) STEP 1: DRILL TWO HOLES IN CEILING Drill two 1” diameter holes through the ceiling at the previously marked locations above the drainback tank. STEP 2: PUSH TUBING THROUGH RIGHT HOLE Push tubing up through hole on right.
Page 27: 6: Tubing & Sensor
2) Solar Collector Installation 6: Tubing & Sensor Installation (continued) STEP 11: DRILL CEILING HOLE FOR ROOF SENSOR Drill a 1/4” hole about 1-1/2” –2” from the right ceiling hole. Push the two-lead roof sensor wire through. For single- tank setups, this wire is attached to the solar controller. STEP 12: PULL WIRE INTO ATTIC Pull wire into attic.
Page 28 2) Solar Collector Installation 7) Solar Controller Installation (continued) Note: Instructions for operating the controller are in the controller box! STEP 1: REMOVE CONTROLLER COVER PLATE Remove cover plate from the controller and mount the solar controller onto the wall or on the solar storage tank. STEP 2: REMOVE LOWER TANK COVER Remove the lower access cover plate from the storage tank.
Page 29: 8: System Startup
2) Solar Collector Installation 8: System Startup STEP 1: OPEN HOT WATER FAUCET Remove the aerator screen from a faucet in the home and turn on the hot water. Alternatively, open the hot water on a bathtub faucet, STEP 2: OPEN MAIN WATER VALVE Open main water valve to house.
Page 30: 9: System Operation
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 reliability for years to come.
Page 31: 10: Troubleshooting
• If the leak is coming from the solar collector panel body, a tube repair kit may be used to Leaks plug one or more tubes. • If the leak is coming from the solar collector header, contact FAFCO for further instruc- tion. • If the leak is coming from the reservoir, other than the reservoir’s relief valve, contact FAFCO for further instruction..
Page 32: Specifications
Specifications SYSTEM: SRCC OG-300 SYSTEM MODEL NUMBERS: Up to date certification numbers can be found at SRCC’s website, www.solar-rating.org. COLLECTOR, SRCC MODEL 2007030A COLLECTOR, SRCC MODEL 2007030B Two 2’ x 12’ Solar Collectors Three 2’ x 8’ Solar Collectors 24” x 144” 24”...
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...