FAFCO Drainback 200 Series User manual

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. This will ensure a trouble-free system that will

maintain the warranty while providing solar energy and savings.

Introduction ..........................................1

Safety .................................................. 2

Code and Certication Requirements.. 3

Parts List..............................................4

Optional Kits ........................................5

Tools Required.....................................5

Overview..............................................6

Installation Checklist .......................... 13

1: Site Selection and Planning ........ 14

2: Roof Mounting ............................. 15

3: Tank Plumbing ............................17

4: ICM Installation ........................... 20

Table of Contents

Introduction

The Solar Water Heating System is designed to provide a signicant portion of the water-heating energy required in a

typical home. Solar energy is absorbed by the solar collectors, and heated water is circulated through the water heater.

Heated water is drawn from the water heater by various household xtures and appliances, such as a clothes washer,

dishwasher, bath, shower, and other xtures.

System performance is affected by available solar energy, the solar collectors’ installed pitch and orientation,

groundwater and ambient air temperatures, and the daily household hot water demand comprised of bath, kitchen,

and laundry use. These conditions, which may vary from home to home even in the same neighborhood, determine

how much energy your solar system will save.

5: Tubing & Sensor

Installation - Below Roof ............. 20

6: Tubing & Sensor

Installation - On Roof .................. 21

7: System Fill ..................................22

8: System Start-up .......................... 22

9: System Operation ....................... 24

10: Troubleshooting .......................... 25

Maintenance ...................................... 25

Specications .................................... 26

Required Labels.................................27

Optional Kit Instructions..................... 28

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 practices on a roof or other elevated structures may

result in falling and serious injury. Working alone increases the chance of an accident happening. Be sure to

have help or someone nearby to assist you.

High Voltage

Some aspects of installation involve working around and with high voltage. Electrical connections to the hot water

heater (if electric) are typically 240 VAC and CAN KILL YOU. Use precautions and ensure that all electricity is

shut off to the area in which you’re working. Use the breaker box and remove the breaker if you have to. Check

with a voltmeter to verify the voltage is off before contacting any electrical connections. Consult with a licensed

electrician if you have any doubts about the process. Check your local building codes.

High Water Pressure and Temperature

Electric and gas water heaters operate at high water pressure and temperature. Be sure to turn off your water

supply and open drain valves to depressurize the system before unthreading or cutting into any part of the water

heater plumbing. Consult a licensed plumber if you have any doubts. Check your local building codes.

Hot water is dangerous. Water temperature to the home

can be regulated by adjusting the temperature control

valve. The recommended set point is 120° F. There is

a scald potential if the temperature control valve is set

too high.

Hot water can produce rst degree burns within:

• 120° F (49°C) more than 5 minutes

• 130° F (54°C) at 20 seconds

• 140° F (60°C) at 3 seconds

• 150° F (66°C) at 1-1/2 seconds

• 160° F (71°C) at less than 1 second

! WARNING !

WATER TEMPERATURE REGULATION

Safety

Extended periods of cold weather, including ambient air temperatures below minus 20oF may cause freezing in

exposed parts of the system. For installatins where plumbing cannot completely drainback tank, add 3 gallons of FAFCO

HTF (Heat Transfer Fliud) which equates to a 35% mixture. Use of any other heat-transfer uid will void warranty, and

may result in poor performance and/or equipment damage. Freeze protection with 35% FAFCO HTF is conservatively es-

timated down to -20oF. 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 uid. It therefore does not promote deposits, corrosion, or degradation of uid mixture.

FREEZE PROTECTION

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 must be listed and

labeled by an accredited listing organization, meet national standards, be labeled with maximum

temperature and pressure, and have minimum R-12 insulation. Do not remove, bypass, or alter

temperature pressure relief valve from backup water heater and/or storage tank.

Certication requirements

Refer to the local authority having jurisdiction and incentive providers for certication requirements.

FAFCO solar collectors and systems listed in Specications, page 25, are certied by the Solar

Rating and Certication Corporation (SRCC), a nationally recognized certication for solar water

heating collectors and systems.

The solar energy system described in this manual, when properly installed and maintained, meets

the minimum standards established by SRCC. This certication does not imply endorsement or

warranty of this product by SRCC.

Specic minimum SRCC installation requirements are listed below:

1. Building penetrations do not impair enclosure function.

2. Building penetrations do not allow insect or vermin intrusion.

3. Building penetrations meet applicable codes and National Roong Contractors Assoc. practices.

4. Structural members penetrated by solar system components meet code.

5. Building materials adjacent to solar components are not exposed to elevated temperatures.

6. Collector mounting is capable of maintaining tilt and azimuth.

7. No excessive shading of collectors.

8. Hangers provide correct tube support.

9. Hangers provide correct tube pitch.

10. Hangers do not compress insulation.

11. Control sensors and wiring are protected.

12. Penetrations through re-rated assemblies do not reduce re resistance below code.

Code and Certication Requirements

Power Supply

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 uid.

Controls the Solar Water Heating System.

Accommodates heat transfer uid expansion, uid contraction, vents air, and

relieves pressure.

Solar collectors

Drainback Tank

PN 08209

Controller

PN 08238

18*

28*

24*

Roof Kit: Two 2’ x 12’ Collectors PN 08881 or Three 2’ x 8’ Collectors PN 08911

Mounting bases

PN 06918

Mounting caps

PN 06919

Roof jack

PN 08211

Roof sealant,

10 oz. tube

PN 08229

Mounting Strap,

40’ roll, PN 08907 1

Collet clips

PN 08819

Roof Sensor

PN 08380

Wire connector

PN 08359

Panel plug

PN 08837

Support liner

PN 08520 1

Elbow ttings

PN 08441 6

Fender washer, Drain-

back Tank, PN 08884

Rubber grommet

Roof Jack, PN 08190

Collector connectors

3-1/2” L, PN 08883

18*

* Quantities in upper left denote 2’x12’ collectors and lower right denote 2’x8’ collectors

Ground Kit PN XXXXX

Teon tape roll

PN 07581

Drain valve

PN XXXXX

Flexible hoses

3’ - PN 08834

Plastic tubing,

80 ft. PN 08613

Tube support

clips PN 08609

Tee, brass, 3/4”

PN 08872

Reducer, brass,

3/4” x 1/2”

PN 08862

Nipple, brass, hex,

1/2” PN 08854

Nipple, brass, hex,

3/4” PN 08869

Screw, self tapping,

2-1/2”, PN 08830

Sensor

PN 08380

2Nipple, brass,

3/4” x 3”

PN 08863

Escutcheon

PN 08462

Sensor cable,

50’ PN 08208

Support liner

PN 08520

Collet clips

PN 08819

Circulation Module

PN 08303 (HH)

PN 08302 (MD)

Circulates the potable water and the solar loop uid. Transfers solar heat

to solar storage tank. Includes:

- Heat exchanger, copper brazed stainless steel, P/N 08782

- Potable loop pump, direct current (DC), P/N 08795

- Solar loop pump, direct current (DC), P/N 08795

Drainback screws,

1/4” x 2”, PN XXXXX 18

Circulation module

screws, 1/4” x 1-1/2” 2

Roong nails, 1” 8

Dip tube with lter

PN XXXXX

Coltector lag screw, st/st,

1/4” x 2”, PN XXXXX

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 nder

#2 & #3 Phillips screw driver

Level

3/4” masonry bit (For tile roof)

3/4” male thread tap

Adjustable wrench

Tubing cutter

Safety glasses

1/8” at blade screw driver

Optional Kits

Parts NOT Provided

Pipe Insulation,

R-2.6 min, 3/4”

thick min

Tube Insulation,

R-2.6 min, 3/4”

thick min, 5/8” ID

Tube Insulation

Support

Solar

storage

tank

A.O. Smith Conservationist

R-24, Promax Plus R16 with

R8 Blanket, or equivalent

Water

heater

A.O. Smith Conservationist

R-24, Promax Plus R16 with

R8 Blanket, or equivalent

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

Collector Add-On Kit

Tile Roof Installation Kit (TRIK)

Solar Storage Tank Kit (Low lead)

Temperature Control Valve Kit (Low lead)

Tubing Extension Kit, 80 ft.

Tube Repair Kit

Kit Name Kit Number Description

758 (Two 2’x12’) or 759 (Three 2’x8’)

767 (Two 2’x12’) or 769 (Three 2’x8’)

730-1

733

734

162-1

48 square feet of collectors with 1 gallon HTF. See pg. 33

Anchors and supports collectors on tile roofs. See pg. 36

Connects water heater to solar storage tank, See pg. 19

Valve required by code. See pg. 18

80 foot of additional tubing for long runs

Rubber plugs for repairing solar collector tubes

There are three basic solar water heating system congurations:

• 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 congura-

tion. Refer to the schematics on the following pages for further details.

Two 2’ x 12’ Solar Collectors

Dual-Tank Single-Tank Single-tank

with

on-demand Heater

Three 2’ x 8’ Solar Collectors

Overview

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.

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. Single element electric water heaters replenish hot water slower than dual element water heaters. Refer to the local plumbing code for minimum water heater size require-

ments. Code typically requires that water heaters be sized to meet a minimum “First Hour Rating” based on the number of bedrooms and bathrooms in a home. For single element water heaters

that don’t have published First Hour Ratings, GAMA/AHRI recommends using 0.75 times the water volume which would require that an 80 gallon tank be used in homes as large as 2 bedroom, 2

bath and that a 120 gallon tank be used in larger homes. It is also recommended to install low ow shower heads which can signicantly reduce hot water demand and save water. Raising the

thermostat setting on water heater element can also increase hot water capacity, but doing so may decrease realized energy savings.