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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.

Summary of Contents for 500 Series

Page 1: ...s 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 ensur...

Page 2: ...ter heater by various household fixtures and appliances such as a clothes washer dishwasher bath shower and other fixtures System performance is affected by available solar energy the solar collectors...

Page 3: ...set point is 120 F There is a scald potential if the temperature control valve is set too high Hot water can produce first degree burns within 120 F 49 C more than 5 minutes 130 F 54 C at 20 seconds 1...

Page 4: ...irements All brand and product names appearing in this manual are registered trademarks of their respective companies Expected operating conditions Temperature Pressure Flowrate MEASUREMENT SYSTEM ACC...

Page 5: ...M 1 Heat Transfer Fluid 3 gallons 1 08890 MODEL FAFCO FAFCO Solar collector 2 x12 08840 08790 FAFCO Pump 08783 FAFCO Heat exchanger 08782 FAFCO 08795 FAFCO 1 PV Panel Kit For PV System Only 08844 FAFC...

Page 6: ...tallation 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...

Page 7: ...ic 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 x 12 Solar Collectors Dual...

Page 8: ...olar 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...

Page 9: ...ooms 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 i...

Page 10: ...ter 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 DE...

Page 11: ...o lar loop fluid The heat exchanger transfers the solar heat to the potable water Integrated Circulation Module ICM cover removed SYSTEM OVERVIEW ON DEMAND FOR GAS OR ELECTRIC COMPONENT OVERVIEW Black...

Page 12: ...e increase in fluid volume On the hottest day at maximum fluid thermal expansion the bladder will be fully deflated and any excess fluid will expel through the one way air vent pressure relief valve A...

Page 13: ...nector bodies Make certain to push the tubing Figure 2 Insertion Depth completely into the fitting until it comes into contact with the internal tubing stop See Figure 2 To disconnect ensure the syste...

Page 14: ...LATION 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 U...

Page 15: ...e solar collectors are flexible and must be installed on a smooth flat surface Any uneven or very rough roof surface will require a flat support surface underneath the solar collectors Composition asp...

Page 16: ...ealant at the penetration to ensure a good seal in a manner acceptable to the metal roof manufacturer Fasten down stringers and substrate to support the collectors Other roof types e g membrane foam t...

Page 17: ...roceeding with this step Chalk mark the location of the upper roof jack hole Break the glue line between the shingles by sliding a large putty knife between the shingles Loosen just enough to fit the...

Page 18: ...pressure relief valve on the side or top of the heater When heater is empty remove hose close drain bibb and relief valve 17 STEP 7 INSTALL BODY STRAPS Apply roof sealant at lag screw location 1 from...

Page 19: ...x 1 2 reducer Apply thread sealant to reducer and install into the side of 3 4 tee as shown STEP 4 CONNECT 3 4 TEE Apply thread sealant and using a 3 4 nipple connect another 3 4 tee in the upright po...

Page 20: ...tricity or gas supply be certain that the tank is full of water Do not use thread sealant on flexible hose connections STEP 3 FILL TANK ACTIVATE ELECTRICAL GAS SUPPLY With the system in normal operati...

Page 21: ...does not require thread sealant All interconnecting hot wa ter piping shall be insulated with R 2 6 or greater insulation 5 Tubing Sensor Installation Below Roof STEP 1 DRILL HOLES IN CEILING AND PUL...

Page 22: ...ter or solar storage tank In both locations securely insert a sensor behind the in sulation against the inner tank wall Replace both covers with the sen sor leads protruding Use caution not to cut the...

Page 23: ...ill port using garden hose adapter Attach piece of solar tub ing to solar system drain port and put end of tubing into an appropriate location to drain Open drain and fill ports Turn on garden hose to...

Page 24: ...all sensor and power wires through the opening on the left side of the cover behind the flexible hose Push the cover on until the four side tabs engage Move the SOLAR switch to the TEST position to t...

Page 25: ...r to set a maximum storage tank water temperature This will depend on household requirements or safety concerns If the water reaches the set maximum temperature during solar operation the solar system...

Page 26: ...ction If the leak is coming from the solar collector panel body a tube repair kit may be used to plug one or more tubes If the leak is coming from the solar collector header contact FAFCO for further...

Page 27: ...eel with copper brazed plates 3 Maximum Testing Pressure 290 psi 4 Maximum Operating Temperature 437 F 5 Single Wall Construction 6 Overall Dimensions 7 51 X 2 87 X 1 94 7 Weight 1 48 Lbs FLEXIBLE HOS...

Page 28: ...27 Required Labels...

Page 29: ...28 Optional Kits Instructions PV Panel Kit 29 Collector Add On Kit 33 Coaxial Adapter Kit 34 Tile Roof Installation Kit TRIK 36...

Page 30: ...Tilt mount angles can be 20 30 or 45 degrees Optimum tilt is equal to the site latitude in degrees For example Phoenix AZ latitude is 33 degrees Parts List 2 5 1 3 4 6 7 8 Item No FAFCO PN QTY Descri...

Page 31: ...enough to allow the PV panel wires to reach under the roof jack into the attic If the panel is to be tilted don t shade the solar collectors Mark the location of each mounting hole and move the angle...

Page 32: ...Asphalt Composition Roof Installation Continued Tile Roof Installation Hold one angle mount in place against the upper end of the panel and place panel vertically in chosen position as shown Mark the...

Page 33: ...e against lower end of panel and lay panel in place against upper angle mount Lay panel inside an gles with wire protrud ing toward upper roof jack Attach with 4 14 x 1 self tapping screws Repeat proc...

Page 34: ...Description Part number Qty 1 Two Collectors 2 x 12 08842 1 2 Base Tie Down 06918 10 3 Cap Tie Down 06919 10 4 Collet Lock 08819 8 5 Connector PP Tube 08883 4 6 Strap 5 8 X 40 Long 08907 1 7 FAFCO He...

Page 35: ...Long Lead Free 08854 1 5 Hose Corrugated ST ST 1 2 X 1 2 X 36 Long 08834 1 6 Filter Coaxial Tube 08855 1 7 Diptube 08777 1 Coaxial Adapter Conversion Kit PN 776 Kit Components STEP 1 INSTALL BRASS CRO...

Page 36: ...provided in the solar water heating system kit to make a 6 finished hose Attach the 6 flexible hose to the nipple Attach the other end of the flexible hose to the threaded fitting on top of the ICM b...

Page 37: ...rilling of tiles Item Description Part number Qty 1 Channel TRIK 3 Collectors 08899 1 2 Clip tile channel rack 08734 10 3 14 X 3 4 self tapping screw 08752 10 4 Screw phillips self tapping 6 x 1 2 L 0...

Page 38: ...the header straps All body channels get bases with slots aligned horizontally for the body straps Snap a vertical chalk line down the roof for aligning the channel ends Each channel gets 3 tile clips...

Page 39: ...total length of 94 for 8 col lectors or 142 for 12 collectors and secure together with a 6 screw Slide sheet until the ends hang over equally above and below the channels B Center sheet equally side t...

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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