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FAFCO 500 Series Installation Manual

Closed loop solar hot water system
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500 Series
Closed Loop
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.
FAFCO © 2010

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Summary of Contents for FAFCO 500 Series

  • Page 1: Installation Manual

    500 Series Closed Loop 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.

  • 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

    HEAT TRANSFER FLUID AND FREEZE PROTECTION Page 21 of this manual contains instructions to mix a minimum 35% FAFCO HTF with potable water. Use of any other heat-transfer fluid will void warranty, and may result in poor performance and/or equipment damage. This mixture is suf- ficient for any freezing conditions per Section 21.5 of the ASHRAE Handbook, Fundamentals which states, “If the fluid is...

  • Page 4: Code And Certification 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 jurisdiction for permitting.

  • Page 5: Parts List

    Parts list Image QTY. COMPONENT BRAND MODEL Solar collector (2’x8’) or FAFCO 08890 Solar collector (2’x12’) 08840 FAFCO 08790 Integrated Circulation Module (ICM) FAFCO FAFCO 08783 - Differential controller - Heat exchanger FAFCO 08782 - Pump FAFCO 08795 08897 FAFCO...

  • Page 6: Optional Kits

    Parts list (Continued) Information Kit Installation Manual - PN 08905 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, Coltector Lag R-2.6 min, 3/4”...

  • Page 7: Overview

    Overview 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’...
  • 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, 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 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 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.
  • Page 11 Solar Loop Inlet DC Potable Loop Pump (FAFCO P/N 08795) Solar Switch Max Water Temp Sensor Error Codes Switch Brazed Plate Heat Exchanger (inside, FAFCO P/N 08782) Temperature Display Button Solar-On LIght Water Temperature DC Differential Temperature Display Controller (FAFCO P/N 08783) Ground, PV, &...
  • Page 12 Overview (continued) SYSTEM OVERVIEW COMPONENT OVERVIEW (ON-DEMAND FOR GAS OR ELECTRIC) Expansion Reservoir Retaining Ring UV Resistant Bladder Vent Cap UV Resistant Air Vent/Pressure Relief Valve, 1 psi Internal Rubber Air Bladder Black UV Resistant Reservoir Fluid Inlet or Outlet Fluid Inlet or Outlet Mounting Holes Function: Installed at the highest point of the system, it serves as expansion tank, air vent and pressure...
  • 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: 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: 1: Site Selection And Planning

    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

    1: Site Selection and Planning (Continued) sheets are available from a FAFCO distributor or local home improvement store. Other roof types (e.g., membrane, foam, tar-and-gravel, slate): Tile For any roofing material not covered here, check with a A Tile Roof Installation Kit (TRIK) should be used on tile roofs.
  • Page 17 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 location as shown.

  • Page 18: 3: Tank Plumbing

    2: Roof Mounting (Continued) STEP 7: 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 3: Tank Plumbing—Single Tank STEP 1: DISCONNECT WATER HEATER PIPING 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” for hot. Connect a flexible hose to the temperature control valve port labeled “MIX”...
  • Page 20 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 21: 4: Icm Installation

    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 the three 2-1/2”...

  • Page 22: 6: Tubing & Sensor

    5: Tubing & Sensor Installation—Below Roof (Continued) STEP 2: CONNECT LOWER ROOF JACK TUBING TO ICM At the ICM cut the tubing to reach top of water heater. Slide on an escutcheon up to the ceiling. Screw swivel elbow fitting of valve assembly (fill valve, check valve, drain valve, and swivel elbow) onto lower right side port of ICM as shown.

  • Page 23: 7: System Fill

    +2F (-17C). Note: FAFCO HTF is the only acceptable fluid for mixing and filling of the system. “Un- der no conditions shall pure unmixed Fafco HTF or any other pure glycol mixture be left in the collector loop. Such a fluid might be flammable under certain conditions and would immediately render the warranty void.”...
  • Page 24 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

    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 POTENTIAL PUMP DAMAGE emphasis on “user friendliness” and reliability for years to come.

  • Page 26: 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 27: Specifications

    First Aid. 1. Type: Brazed plate, 10 plates. 10. FAFCO system is overheat protected and has little metal 2. Material: AISI 316 stainless steel with copper brazed plates. in contact with fluid. It therefore does not promote deposits, 3.

  • Page 28: Required Labels

    Required Labels...

  • Page 29: Optional Kit Instructions

    Optional Kits Instructions PV Panel Kit ........29 Collector Add-On Kit ......33 Coaxial Adapter Kit ......34 Tile Roof Installation Kit (TRIK) ..36...

  • Page 30: Pv Panel Kit

    For example: Phoenix AZ latitude is 33 degrees. Parts List Item No. FAFCO PN# Description 08845 PV panel, 40W, FAFCO P/N 08845 08846 Angle, right flush, PV panel 08847 Angle, left flush, PV panel 08752 #14 x 1” phil hd self tapping screw...
  • Page 31 PV Panel Kit Asphalt Composition Roof Installation Step 1: Choose Location Step 2: Layout Angle Mounts The PV panel The two angle should ideally be mounts are designed placed above the for the lag screws to solar collectors. be affixed into two Alternatively, choose roof trusses on 24- an unshaded area,...
  • Page 32 PV Panel Kit Asphalt Composition Roof Installation (Continued) Step 5: Run PV Panel Wire Into Attic Step 6: Run 50’ PV Wire Run PV panel wires Run 50’ PV wire from ICM, alongside sensor wire, alongside roof sensor and connect to PV panel wire in attic with wire wire under roof jack into nuts.
  • Page 33 PV Panel Kit Tile Roof Installation (Continued) Step 5: Seal And Secure Angle Step 6: Place Lower Angle Mount Place a nickel size Hold lower angle daub of roof seal- mount in place ant at each hole. against lower end Replace angle and of panel and lay secure to tiles with...

  • Page 34: Collector Add-On Kit

    Cap, Tie Down 06919 Collet Lock 08819 Connector, PP Tube 08883 Strap, 5/8” X 40’ Long 08907 FAFCO Heat Transfer Fluid, 1 Gallon 08897 Three 8-foot Collectors - PN 759 Item Description Part number Three Collectors, 2’ x 8’ 08891...

  • Page 35: Coaxial Adapter Kit

    Coaxial Adapter Conversion Kit Overview 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 the solar storage tank which draws water to the ICM through the cold water dip tube.
  • Page 36 Coaxial Adapter Conversion Kit STEP 6: CONNECT THE 6’ HOSE TO ICM STEP 5: INSTALL REDUCER Using the ½” nipple, Apply thread seal- couple the 3’ long flex hose ant to the remaining provided in the adapter reducer and install in kit to the 3’...

  • Page 37: Tile Roof Installation Kit (Trik)

    Tile Roof Installation Kit (TRIK) Overview The TRIK mounting systems can be installed on curved Note: Use an additional TRIK for each Collector Add- and flat tile roofs and can only be used for vertical On Kit. All necessary materials are provided in the installations.
  • Page 38 Tile Roof Installation Kit (TRIK) Step-by-Step Installation Step 1: Attach bases to channels Step 2: Determine layout The configura- A. Place upper tions depicted in header channel the installation against the lip of sequence show the second tile 8-Foot Collectors. row down from the Attach bases to ridge.
  • Page 39 Tile Roof Installation Kit (TRIK) Step-by-Step Installation Step 7: Lay corrugated sheet Step 8: Mount Collectors A. Lay two pieces Lay collectors on of the corru- substrate with top gated sheet on headers hanging the channels over substrate. with overlapped Install and adjust ends.
  • 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...

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