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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 

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

Controller Features:

1. Sensor Error Codes

2. Temperature Display Button

3. Continuous Digital Display of Water Storage 

    Tank Temperature

4. Solar Switch

5. Max Water Temp Switch

6. Solar On Light

Controller Operation:

The system operates automatically, continuously displaying the upper tank WATER TEMPERATURE. The system will 

activate whenever the roof temperature is at least 10 hotter than the lower tank temperature. The system will continue 

to operate automatically until the tank reaches the selected MAX WATER TEMP or the roof temperature is only 4 de-

grees hotter than the lower tank temperature. At that time, the system will shut-off automatically, the green SOLAR ON 

light will go off, and the WATER TEMPERATURE will continue to be displayed. The system will reactivate whenever 

the roof temperature is at least 10 hotter than the lower tank temperature.

Solar Setting:

The SOLAR switch is normally set in the AUTO position, and should remain set this way for automatic operation. The 

TEST position is normally for installation and maintenance purposes only and should only be used to test the system. 

The OFF position is for maintenance only.

Maximum Tank Temp Setting:

This switch permits the user 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 will shut off automatically. Optional maximum temperature settings are 120° F, 135° F and 150° F. 

Temperature Display:

The upper tank temperature is continuously displayed. View other temperatures by pressing the TEMP DISPLAY

push button. “U”, “L” or “r” will be displayed representing the upper tank, lower tank or roof, followed by the tempera-

ture. Display will revert back to upper tank temperature after a short time period.

Sensor Monitoring:

A faulty or disconnected UPPER TANK, LOWER TANK or ROOF sensor will be indicated by the display flashing SE-

U, SE-L or SE-r. The system will automatically shut off, and the display will flash until the sensor has been repaired,

replaced or re-connected.

System Self Monitoring

The system continuously monitors for water temperature increase while the pumps are operating.  If the controller 

senses the water is not heating after 4 hours of system operation, the system will shut off and display “FLO” indicating 

the water or heat transfer fluid is not flowing properly through the system.  Contact your installer for system evaluation 

and repair.

Operating Indicators

To determine if the system is operating properly and providing solar heated water, verify the top tank water temperature 

is warm.  For single tank systems, verify the top tank water temperature is higher than lower tank water temperature 

when the system is activated. 

If the circulation module is turned on 
by this controller when no water is in 

the system the pumps can be 

permanently damaged.

POTENTIAL PUMP DAMAGE

2

3

5

4

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Содержание 500 Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 28: ...27 Required Labels...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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