FAFCO 500 Series User manual

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. 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

Page 21 of this manual contains instructions to mix a minimum 35% FAFCO HTF with potable water. Use of any other

heat-transfer uid will void warranty, and may result in poor performance and/or equipment damage. This mixture is suf-

cient for any freezing conditions per Section 21.5 of the ASHRAE Handbook, Fundamentals which states, “If the uid is

being used to prevent equipment damage during idle periods in cold weather, such as winterizing coils in an HVAC system,

35% propylene glycol is sufcient. These concentrations will allow the uid to freeze. As the uid freezes, it forms a slush

that expands and ows into any available space. Expansion volume must be included with this type of protection. If the

application requires that the uid remain entirely liquid, use a concentration with a freezing point 5oF below the lowest ex-

pected temperature. Avoid excessive glycol concentration because it increases initial cost and adversely affects the uid’s

physical properties.” Freeze protection is conservatively estimated 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.

HEAT TRANSFER FLUID AND FREEZE PROTECTION

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 jurisdiction for permitting.

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.

SRCC model numbers

Up to date model numbers can be found at SRCC’s website, www.solar-rating.org.

OG-100:

- 2’X12’ COLLECTOR: SRCC MODEL 2007030A AND 2’X8’ COLLECTOR: SRCC MODEL 2007030B

OG-300:

Code and Certication Requirements

Power Supply

* All brand and product names appearing in this manual are registered trademarks of their respective companies.

Expected operating conditions

Temperature

Pressure

Flowrate

MEASUREMENT SYSTEM ACCESS POINT EXPECTED VALUE

Controller display

Expansion reservior

Solar or Potable Loop

DT greater than 10oF when operating

Less than 1 psi

1 to 2 gpm

Solar

Collector

Area

(sq-ft)

Solar

Tank

Volume

(gal)

2’x12’ Collectors 2’x8’ Collectors

Electric Water Heater Gas Water Heater Electric Water Heater Gas Water Heater

Dual Tank Single Tank Dual Tank On-Demand Dual Tank Single Tank Dual Tank On-Demand

A/C

48 50 AC24UX2-50E-50S AC24UX2-50E AC24UX2-50G-50S AC24UX2-TG-50S AC16UX3-50E-50S AC16UX3-50E AC16UX3-50G-50S AC16UX3-TG-50S

48 80 AC24UX2-50E-80S AC24UX2-80E AC24UX2-50G-80S AC24UX2-TG-80S AC16UX3-50E-80S AC16UX3-80E AC16UX3-50G-80S AC16UX3-TG-80S

48 120 - AC24UX2-120E - AC24UX2-TG-120S - AC16UX3-120E - AC16UX3-TG-120S

96 50 AC24UX4-50E-50S AC24UX4-50E AC24UX4-50G-50S AC24UX4-TG-50S AC16UX6-50E-50S AC16UX6-50E AC16UX6-50G-50S AC16UX6-TG-50S

96 80 AC24UX4-50E-80S AC24UX4-80E AC24UX4-50G-80S AC24UX4-TG-80S AC16UX6-50E-80S AC16UX6-80E AC16UX6-50G-80S AC16UX6-TG-80S

96 120 - AC24UX4-120E - AC24UX4-TG-120S - AC16UX6-120E - AC16UX6-TG-120S

144 50 AC24UX6-50E-50S AC24UX6-50E AC24UX6-50G-50S AC24UX6-TG-50S AC16UX9-50E-50S AC16UX9-50E AC16UX9-50G-50S AC16UX9-TG-50S

144 80 AC24UX6-50E-80S AC24UX6-80E AC24UX6-50G-80S AC24UX6-TG-80S AC24UX6-50E-80S AC16UX9-80E AC16UX9-50G-80S AC16UX9-TG-80S

144 120 - AC24UX6-120E - AC24UX6-TG-120S - AC16UX9-120E - AC16UX9-TG-120S

48 50 PV24UX2-50E-50S PV24UX2-50E PV24UX2-50G-50S PV24UX2-TG-50S PV16UX3-50E-50S PV16UX3-50E PV16UX3-50G-50S PV16UX3-TG-50S

48 80 PV24UX2-50E-80S PV24UX2-80E PV24UX2-50G-80S PV24UX2-TG-80S PV16UX3-50E-80S PV16UX3-80E PV16UX3-50G-80S PV16UX3-TG-80S

48 120 - PV24UX2-120E - PV24UX2-TG-120S - PV16UX3-120E - PV16UX3-TG-120S

96 50 PV24UX4-50E-50S PV24UX4-50E PV24UX4-50G-50S PV24UX4-TG-50S PV16UX6-50E-50S PV16UX6-50E PV16UX6-50G-50S PV16UX6-TG-50S

96 80 PV24UX4-50E-80S PV24UX4-80E PV24UX4-50G-80S PV24UX4-TG-80S PV16UX6-50E-80S PV16UX6-80E PV16UX6-50G-80S PV16UX6-TG-80S

96 120 - PV24UX4-120E - PV24UX4-TG-120S - PV16UX6-120E - PV16UX6-TG-120S

144 50 PV24UX6-50E-50S PV24UX6-50E PV24UX6-50G-50S PV24UX6-TG-50S PV24UX6-50E-50S PV16UX9-50E PV16UX9-50G-50S PV16UX9-TG-50S

144 80 PV24UX6-50E-80S PV24UX6-80E PV24UX6-50G-80S PV24UX6-TG-80S PV24UX6-50E-80S PV16UX9-80E PV16UX9-50G-80S PV16UX9-TG-80S

144 120 - PV24UX6-120E - PV24UX6-TG-120S - PV16UX9-120E - PV16UX9-TG-120S

Power Supply

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

Roof sensor

sleeve PN 08910

Panel plug

PN 08837

Support liner

PN 08520 1

Elbow ttings

PN 08441 6

Reservoir Fender

washer, 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

Parts list

COMPONENT QTY.

BRAND

- Differential controller

Solar collector (2’x8’) or

Expansion reservoir

Integrated Circulation Module (ICM)

Heat Transfer Fluid 3 gallons

08890

MODEL

FAFCO

Solar collector (2’x12’) 08840

08790

FAFCO

- Pump

08783

FAFCO

- Heat exchanger 08782

FAFCO

08795

FAFCO

PV Panel Kit (For PV System Only) 08844

FAFCO

08897

FAFCO

08797

FAFCO

A.O. Smith or

equivalent

Conservationist,

Promax Plus, or

equivalent

Solar Storage tank (not provided)

Image

08845

FAFCO

- PV Panel

Ground Kit PN 08882

Teon tape roll

PN 07581

Fill and drain

valves PN 08836

Flexible hoses

3’ - PN 08834

5’ - PN 08835

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

Check valve,

PN 09003

Nipple, brass, hex,

3/4” PN 08869

Elbow, swivel

PN 08305

Filter, self-clean

PN 08833

Power Supply

PN 08784

Screw, self

tapping, 2-1/2”

PN 08830

1Cable ties

PN 08184 4

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

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

Coltector Lag

screw, stainless

steel, 1/4” x 2”

Reservoir Lag

screw, stainless

steel, 1/4” x 3-1/2”

Roong nails, 1” 8

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

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

Collector Add-On Kit

Tile Roof Installation Kit (TRIK)

Solar Storage Tank Kit (Low lead)

Temperature Control Valve Kit (Low lead)

Coaxial Tank Adapter Conversion Kit

Electric Fill Kit

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

776

777

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

Enables both connections at tank drainport. See pg. 34

Pumps HTF into system. See pg. 22

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 gas or electric

• Single-tank electric

• Single-tank with on-demand gas heater

Components vary based on conguration. 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.

Temperature

control valve

Water heater

Storage Tank

Integrated

Circulation Module

(ICM)

Bypass

valves

Expansion

reservoir

Self Cleaning Filter

From solar collectors

To solar collectors

Cold water supply

Fill valve

Cold water

shut-off valve

Temperature

Control Valve

Bypass valves

Hot water to home

Drain valve

P/T Valve

Air Vent/Pressure

Relief Valve

Solar collectors

Check valve

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. 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 requirements. 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.

Solar collectors

Water heater

Expansion

reservoir

Integrated

Circulation Module

(ICM)

Temperature

Control Valve

Air Vent/Pressure

Relief Valve

From solar collectors

To solar collectors

Hot water to home Cold water supply

Self

Cleaning

Filter

Cold water shut-off valve

Fill valve

Drain valve

P/T Valve

Temperature

Control Valve

Check Valve

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 a solar water heating system, it must have a

temperature-modulating gas burner. A temperature control valve is required for this conguration, but depending on

the brand and model of on-demand heater, the valve placement may vary. Refer to the manufacturer’s instructions for

compatibility with solar water heating systems and proper placement of the temperature control valve.

SYSTEM OVERVIEW

(ON-DEMAND FOR GAS OR ELECTRIC)

SINGLE TANK WITH ON-DEMAND HEATER

Overview (continued)

Temperature

control valve

Gas

On-demand

Heater

Integrated

Circulation Module

(ICM)

Expansion

reservoir

Bypass valves

Polymer Solar

Collector

Storage Tank

Air Vent/Pressure

Relief Valve

Fill valve

Drain valve

Gas

On-demand

Heater

Temperature

control valve

To solar collectors

From solar collectors

Cold

water

supply

Cold water

shut-off

valve

Hot water

to home

Bypass

valves

P/T valve

Self cleaning

lter

Check valve

Table of contents

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