Lochinvar SDT065 - 119, SET065 - 119 User Manual

Installation & Operation
Manual
Models: SDT/SET065 - 119
This manual must only be used by a qualified heating installer / service technician. Read all instructions before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.
WARNING
Save this manual for future reference.
SDT-SET-I-O Rev B
SDT
Solar Dual Coil Tank
SET
Solar Electric Tank
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
2
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.
HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3
1. GENERAL INFORMATION
Operating Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Single-Wall Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . 4
2. PRE-INSTALLATION
Locating the Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Recommended Clearances . . . . . . . . . . . . . . . . . . . . . . . . 5
3. BOILER SIDE PIPING (SDT MODELS)
Zone with Circulator to Aquastat . . . . . . . . . . . . . . . . . . . . 6
Zone with Valve to Aquastat . . . . . . . . . . . . . . . . . . . . . . . 6
DHW Prioritization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Multiple Tank Connections (Boiler Side) . . . . . . . . . . . . . . 6
Table 3A - 3B - Pressure Drop Charts . . . . . . . . . . . . . 7
Table 3C - Pressure Drop Values . . . . . . . . . . . . . . . . . 7
Piping Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
4. DOMESTIC SIDE (TANK) PIPING
Basic Domestic Piping . . . . . . . . . . . . . . . . . . . . . . . . . 11
Multiple Tank Domestic Water Piping . . . . . . . . . . . . . 11
Domestic Water Piping for Distant Fixtures . . . . . . . . .11
Anti-scald Valves (Mixing Valves) . . . . . . . . . . . . . . . . 12
Install Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Temperature and Pressure (T&P) Relief Valve . . . . . 12
Table 4A - Minimum Relief Valve (AGA Rating) . . 13
5. WIRING
Electrical Connection and Thermostat Setup . . . . . . . . . .16
Indirect Water Heater Sensor Setup (Knight Boiler) . . . . 18
Install Tank Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Indirect Water Heater Controlled Using Aquastat and Zone
Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. START-UP AND CHECK-OUT . . . . . . . . . . . . . . . . . 20
7. MAINTENANCE
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 21
To Fill the Water Heater . . . . . . . . . . . . . . . . . . . . . . . 21
To Drain the Water Heater . . . . . . . . . . . . . . . . . . . . . 21
8. PERFORMANCE DATA
Performance Data Charts . . . . . . . . . . . . . . . . . . . . . . . . 22-24
9. High Output Piping
High Domestic Hot Water Usage . . . . . . . . . . . . . . . . 25
Series Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-26
Parallel Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-27
REVISION NOTES . . . . . . . . . . . . . . . . . . . . . Back Cover
Contents
SDT/SET Installation & Operation Manual
Please read before proceeding
Installer – Read all instructions before installing. Perform steps in the order given.
Have this indirect water heater serviced/inspected by a qualified service technician, at least annually.
Failure to comply with the above could result in severe personal injury, death or substantial property damage.
Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.
When servicing the indirect water heater –
• To avoid severe burns, allow the appliance to cool before performing maintenance.
Indirect water heater operation –
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.
• Do not use this appliance if any part has been under
water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.
When calling or writing about the appliance – Please have the indirect water heater model and serial number from the indirect water heater rating plate.
Consider piping and installation when determining appliance location.
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Factory warranty (shipped with appliance) does not apply to appliances improperly installed or improperly operated.
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
• Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
WARNING
NOTICE
WARNING
WARNING
Hot Water Can Scald!
Water heated to temperatures for clothes washing, dish washing, and other sanitizing needs can scald and cause permanent injury.
Children, elderly, and infirm or physically handicapped persons are more likely to be permanently injured by hot water. Never leave them unattended in a bathtub or shower. Never allow small children to use a hot water tap or draw their own bath.
If anyone using hot water in the building fits the above description, or if state laws or local
codes require certain water temperatures at hot water taps, you must take special precautions:
Use lowest possible temperature setting.
Install some type of tempering device, such as an automatic mixing valve, at hot water tap or water heater. Automatic mixing valve must be selected and installed according to valve manufacturer’s recommendations and instructions.
Water passing out of drain valves may be extremely hot. To avoid injury:
Make sure all connections are tight.
Direct water flow away from any person.
Protection Must Be Taken Against Excessive Temperature and Pressure!
--Installation of a Temperature & Pressure (T&P) relief valve is required.
3
The following chart details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.
APPROXIMATE TIME / TEMPERATURE
RELATIONSHIPS IN SCALDS
120°F More than 5 minutes
125°F 1 1/2 to 2 minutes
130°F About 30 seconds
135°F About 10 seconds
140°F Less than 5 seconds
145°F Less than 3 seconds
150°F About 1 1/2 seconds
155°F About 1 second
1 General Information
The Lochinvar SDT/SET series indirect water heater (FIG. 1-1) is designed to generate domestic hot water in conjunction with a solar panel using forced circulation with a backup heat source. This indirect water heater consists of a 316L Stainless Steel tank in which a smooth 304L stainless steel coil is located (Table 1A). Solar heating fluid is pumped through the coil and heats the water in the tank. If the solar panel cannot produce enough heat, the backup source should supply hot water. This tank is not intended for use in pool heating applications or for heating any fluid other than water. It is also not intended for use in gravity hot water heating systems.
Table 1A
Component Materials
Component Material
Ta n k 316L Steel Stainless Steel
Coil 304L Stainless Steel
Insulation Polyurethane
Jacket ABS
Figure 1-1 Lochinvar SDT and SET Series Indirect Water Heaters
Single-Wall Heat Exchanger
National Standard Plumbing Code
Single-wall heat exchangers in water heaters comply with the National Standard Plumbing Code provided that:
boiler water (including additives) is practically non-toxic, having a toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, and
boiler water pressure is limited to a maximum of 30 psig by approved relief valve.
Uniform Plumbing Code
Single-wall heat exchangers are permitted if they satisfy all of the following requirements --
1. The heat transfer medium is potable water or contains only substances which are recognized as safe by the U.S. Food and Drug Administration.
2. The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system.
3. The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used in the heat transfer medium.
Other heat exchanger designs may be permitted where approved by the Administrative Authority.
Operating Restrictions:
Maximum domestic hot water temperature is 194°F.
Maximum boiler water temperature is 210°F.
Maximum working pressure for the vessel tank is 150 psig.
SDT/SET Installation & Operation Manual
4
“G”
“F”
SOLAR DUAL
COIL
“E”
“D”
“C”
1. RELIEF VALVE CONNECTION
2. HOT WATER OUTLET
3. BOILER WATER IN
4. BOILER WATER OUT
5. DRAIN / COLD WATER INLET
6. SOLAR WATER IN
7. SOLAR WATER OUT
8. ELEMENT
o
o
22.5
45
“B”
“A”
“I”
1 - 1/2” FPT
3/4” FPT
AQUASTAT WELL
1” MPT
SOLAR SENSOR
1” MPT
1 - 1/2” MPT
PAR T N O.
SDT065
SDT080 SDT119 SET065 SET090 SET119
1” MPT
1” MPT
“A”
(in.) 3 5/16 3 5/16 3 5/16 3 5/16
3 5/16 3 5/16
SOLAR ELECTRIC
2
1
3
8
6
“G”
7
5
“B”
(in.) 9 1/8 9 1/8 9 3/8 9 1/8 9 1/8 9 3/8
“F”
“C”
(in.) 27 15/16 27 15/16
31 11/16 27 15/16 27 15/16 31 11/16
“H”
WEIGHT
45
“H”
(in.) N/A N/A N/A
59 7/8 59 7/8 59 7/8
o
“I”
FULL OF WATER
(in.) 24 24 28 24 24 28
“I”
1 - 1/2” FPT
3/4” FPT
1” MPSF
1” MPT
SOLAR SENSOR
1” MPT
1 - 1/2” MPT
(LBS)
820 921
1268
820 921
1268
2
1
8
6
7
5
“E”
“D”
(in.)
(in.)
33 5/8
47 3/16
53 3/4
40 3/16
54 1/2
37 7/16
N/A
N/A N/A
N/A N/A
N/A
“C”
“B”
“A”
“F” (in.)
52 5/16
61 13/16
60 1/8
52 5/16
61 13/16
60 1/8
“G”
(in.) 59 7/8 69 3/8
68 3/16
59 7/8 69 3/8
68 3/16
22.5
o
5
2 Pre-installation
1. The installation must conform to the instructions in this manual and all applicable local, state, provincial, and national codes, laws, regulations, and ordinances. Installations in Canada must conform to B149.2 Installation Code.
2. Be certain the domestic water supply to the tank has physical and chemical characteristics that fall within the limits shown in Table 2A. Where questions exist as to the composition of the water on the job, a qualified water treatment expert should be consulted.
Water with characteristics outside the limits shown in Table 2A may severely shorten the life of the tank due to corrosion. Damage to tanks in such cases is not covered under warranty.
3. Read and understand all installation requirements in this manual.
Table 2A
Water Chemistry Requirements
Water used in the tank must have characteristics falling within the following limits:
Characteristic Min. Max.
Ph 6.0 8.0
Chloride (PPM) -- 80
CAUTION
Locating the Tank
1. Choose a location for your water heater centralized to the piping system. You must also locate the SDT/SET water heater where it will not be exposed to freezing temperatures. Additionally, you will need to place the water heater so that the controls, drain, and inlet/outlets are easily accessible. This appliance must not be installed outdoors, as it is certified as an indoor appliance, and must also be kept vertical on a level surface.
2. Keep distance between boiler and water heater to a minimum to: a. reduce piping heat loss b. provide minimal friction loss
3. Figure 1-1 on page 4 shows the weights of all the tanks filled with water. Make sure that the location chosen for the tank is capable of supporting it.
This appliance must be placed where leakage from the relief valve, leakage from the related piping, or leakage from the tank or connections, will not result in damage to the surrounding areas, or to the lower floors of the building. A water heater should always be located in an area with a floor drain or installed in a drain pan suitable for water heaters. Lochinvar shall not be held liable for any such water damage.
CAUTION
Failure to properly support the tank could result in property damage or personal injury.
WARNING
4. The tank may be located some distance from the boiler provided the pump is designed to provide the flow called for in Table 3B (page 7)- Pressure Drop Values, through the coil. The further the tank is from the boiler, the longer the response of the boiler will be to a call from the tank zone. Insulate piping between the boiler and the tank.
Recommended Clearances
The installation location must provide adequate clearances for servicing and proper operation of the water heater. A 12 inch vertical clearance is recommended from the top of the water heater. A zero clearance is allowed for the sides of the water heater. However, boiler, electrical, and servicing clearances must be figured when locating the water heater.
Minimum Clearance to the Element Cover
See FIG 2-1. Clearances must be a minimum of 24-inches to allow for element removal and replacement on SET model.
SDT/SET Installation & Operation Manual
Figure 2-1 Element Cover Clearances
24” MIN CLEARANCE FROM
ELEMENT COVER
(SET Models)
6
Multiple Tank Connections (Boiler Side)
Multiple tank installations must be done in the “reverse-return” manner. The reason for this is to create the same pressure drop (and therefore, the same flow) through the coil of each tank. The boiler manifold piping must be sized so that each coil has the flow rate called for in Table 3B.
Because the pressure drop through tank coils varies from size to size, it is hard to predict the flow rate that will be developed through each coil when two tanks of different sizes are placed in the same manifold. For this reason it is best not to mix tanks of different sizes in the same zone if their recovery is critical.
3 Boiler Side Piping (SDT models)
Figures 3-1 thru 3-4 show typical boiler side piping for several common situations. Regardless of which system is used it is imperative that the flow rates called for in Table 3C are developed through the coil. This requires properly sized piping and a properly sized pump.
The system shown in FIG’s 3-1 thru 3-4 are described below:
Zone with Circulator to Aquastat
This system is like the circulator zone system on a straight heat job except that one of the zones goes to the tank instead of radiation. As on any circulator zone system check valves should be installed in each zone to prevent unwanted circulation through zones which are not calling for heat. Figure 3-1 on page 8 illustrates typical circulator zone piping.
Zone with Valve to Aquastat
As with the circulator zone system, this system is just like a standard heating zone system except that one of the zones is connected to the tank coil as shown in FIG. 3-2 on page
9. The system circulator must be large enough to move boiler water through the coil regardless of the flow rate required through the heating zones.
DHW Prioritization
This piping system is designed to provide direct hot water priority over the other zones in the heating system. When there is a Domestic Hot Water (DHW) call for heat, the Knight control will shut off the boiler circulator and activate the domestic hot water circulator. Once the DHW demand is satisfied, the boiler circulator will be readjusted as demand requires. The circulator must be large enough to move the boiler water through the coil in the tank, and it must meet the minimum boiler flow requirments. The recommended piping for a DHW priority system is depicted in FIG. 3-3 on page 10.
SDT/SET Installation & Operation Manual
7
SDT/SET Installation & Operation Manual
Table 3A
Pressure Drop Chart SDT/SET065-080
Table 3C
Pressure Drop Values
MODEL
COIL
CONN.
(IN)
COIL
LENGTH
(FT)
SQ FT
SURFACE
AREA
PRESSURE DROP
SOLAR COIL
(FT / HD)
COIL
LENGTH
(FT)
SQ FT
SURFACE
AREA
PRESSURE DROP
BOILER COIL
(FT / HD)
5
GPM8 GPM
12
GPM16GPM20GPM
5
GPM8 GPM
12
GPM16GPM20GPM
SDT065
1 41.5 13.5 0.61 1.57 3.53 6.27 9.8 28 9.2 0.4 1.03 2.31 4.1 6.41
SDT080
1 41.5 13.5 0.61 1.57 3.53 6.27 9.8 28 9.2 0.4 1.03 2.31 4.1 6.41
SDT119
1 67.3 22.0 .73 1.87 4.22 7.5 11.71 48.5 16 0.61 1.57 3.53 6.27 9.8
SET065
1 41.5 13.5 0.61 1.57 3.53 6.27 9.8
SET080
1 41.5 13.5 0.61 1.57 3.53 6.27 9.8
SET119
1 67.3 22.0 .73 1.87 4.22 7.5 11.71
3 Boiler Side Piping (SDT models) (continued)
Table 3A Pressure Drop Chart SDT/SET065-080
Table 3C Pressure Drop Values SDT/SET065-119
Table 3B
Pressure Drop Chart SDT/SET119
Table 3B Pressure Drop Chart SDT/SET119
SDT / SET065 - 080 FRICTION LOSS
10.00
10.00
8.00
8.00
6.00
6.00
HDFT/
FT/HD
4.00
4.00
2.00
2.00
0.00
0.00
SDT / SET065 - 080 FRICTION LOSS
5 8 12 16 20
GPM
SOLAR
SOLAR
COIL
BOILER
BOILER
SDT
/
COIL
COIL
COIL
FT/HD
12.00
10.00
8.00
6.00
4.00
2.00
0
5 8 12 16 20
GPM
SET119 FRICTION
LOSS
SOLAR
COIL
BOILER
COIL
SDT/SET Installation & Operation Manual
8
Figure 3-1 Piping Diagram Zoned with Circulators
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
NOTICE
3 Boiler Side Piping (SDT models)
NOTICE
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
ZONE #1
MAKE UP WATER
DRAIN POINT
(TYPICAL)
BALL VALVE
(TYPICAL)
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
AIR SEPARATOR
EXPANSION
TANK
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
DRAIN
PRESSURE
RELIEF VALVE
GAS SUPPLY
PRESSURE
GAUGE
SYSTEM SUPPLY
SENSOR
(WHEN USED)
NOT TO EXCEED 4 PIPE DIA.
OR A MAXIMUM OF 12" APART
Y-STRAINER
FLOW CHECK
BOILER CIRCULATOR
VALVE
BOILER BACKUP
HEAT EXCHANGER
( SDT MODELS ONLY )
SOLUTION
BOILER
SOLAR
HEAT EXCHANGER
ZONE#2ZONE
#3
HOT
WATER
OUT
SQUIRE
ZONE
#4
ZONE CIRCULATORS
(TYPICAL)
ANTI-SCALD MIXING VALVE
COLD
WATER
IN
TEMPERATURE/
PRESSURE
RELIEF VALVE
BOILER
TANK SENSOR /
AQUASTAT
SOLAR SENSOR
CHECK VALVE
TEMPERATURE/ PRESSURE GAUGE (TYPICAL)
RECIRCULATION
CHECK VALVE
DRAIN ( FIELD SUPPLY )
AUXILIARY CATCH PAN
FROM
SOLAR
TO
SOLAR
PUMP
Installation & Operation Manual
9
Figure 3-2 Piping Diagram Zoned with Valves
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
NOTICE
3 Boiler Side Piping (SDT models) (continued)
NOTICE
Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.
ZONE #1
REDUCING VALVE
BACKFLOW
PREVENTER
MAKE UP WATER
DRAIN POINT
(TYPICAL)
BALL VALVE
(TYPICAL)
PRESSURE
SYSTEM SUPPLY
AIR SEPARATOR
EXPANSION
(TYPICAL)
TEMPERATURE /
PRESSURE
GAUGE
SENSOR
(WHEN USED)
TANK
UNION
DRAIN
PRESSURE
RELIEF VALVE
GAS SUPPLY
PRESSURE
GAUGE
SYSTEM
CIRCULATOR
NOT TO EXCEED 4 PIPE DIA.
OR A MAXIMUM OF 12" APART
Y-STRAINER
BOILER CIRCULATOR
BOILER BACKUP
HEAT EXCHANGER
( SDT MODELS ONLY )
SOLUTION
BOILER
SOLAR HEAT EXCHANGER
ZONE
#2
SQUIRE
ZONE
#3
HOT
WATER
OUT
ZONE
#4
ZONE VALVES
(TYPICAL)
DIFFERENTIAL
PRESSURE
VALVE (IF USED)
ANTI-SCALD MIXING VALVE
COLD
WATER
IN
TEMPERATURE/
PRESSURE
RELIEF VALVE
BOILER
TANK SENSOR /
AQUASTAT
SOLAR SENSOR
CHECK VALVE
TEMPERATURE/ PRESSURE GAUGE (TYPICAL)
RECIRCULATION
CHECK VALVE
DRAIN ( FIELD SUPPLY )
AUXILIARY CATCH PAN
BYPASS
FROM
SOLAR
TO
SOLAR
PUMP
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