Lochinvar SET080 Installation Manual

SDT-SET-I-O Rev D

Installation & Operation

Manual

Models: SDT/SET065 - 119

CAUTION: The heat transfer

medium must be water or other nontoxic fluid having a toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, 5th edition.

The pressure of the heat transfer medium must be limited to a maximum of 30 PSIG by an approved safety or relief valve.

SDT

Solar Dual Coil Tank

 WARNING

SET

Solar Electric Tank

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.

Save this manual for future reference.

Contents

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 and Connect 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

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.

 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.

Please read before proceeding

 WARNING

NOTICE

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.

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.

SDT/SET Installation & Operation Manual

 WARNING

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.

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.

 WARNING

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.

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.

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

SDT/SET Installation & Operation Manual

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.

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.

Table 1A

Component Materials

Component Material

Tank 316L Steel Stainless Steel

Coil 304L Stainless Steel

Insulation Polyurethane

Jacket Polypropylene / ABS

Single-Wall Heat Exchanger

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.

Figure 1-1 Lochinvar SDT and SET Series Indirect Water Heaters

“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

22.5

“B”

“A”

“I”

1 - 1/2” FPT

3/4” FPT

AQUASTAT WELL

1” MPT

SOLAR SENSOR

1” MPT

1 - 1/2” MPT

PAR T NO .

SDT065

SDT080

SDT119 SET065 SET090 SET119

1” MPT

“A”

(in.) 3 5/16 3 5/16 3 5/16 3 5/16

3 5/16 3 5/16

SOLAR ELECTRIC

“G”

“B”

(in.) 9 1/8 9 1/8 9 3/8 9 1/8 9 1/8 9 3/8

WEIGHT

“H”

(in.) N/A N/A N/A

59 7/8 59 7/8 59 7/8

“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

“D” (in.)

33 5/8

40 3/16

37 7/16

N/A N/A N/A

“B”

“A”

“E” (in.)

47 3/16

53 3/4 54 1/2

N/A N/A N/A

“C”

(in.) 27 15/16 27 15/16

31 11/16 27 15/16 27 15/16 31 11/16

“F”

“H”

“C”

“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

2 Pre-installation

SDT/SET Installation & Operation Manual

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.

CAUTION

3. Read and understand all installation requirements in this manual.

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.

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

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.

CAUTION

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.

Figure 2-1 Element Cover Clearances

24” MIN CLEARANCE FROM

ELEMENT COVER

(SET Models)

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.

 WARNING

Failure to properly support the tank could result in property damage or personal injury.

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

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 systems 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.

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.

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

3 Boiler Side Piping (SDT models) (continued)

Table 3A Pressure Drop Chart SDT/SET065-080

Table 3A

Pressure Drop Chart SDT/SET065-080

SDT / SET065 - 080 FRICTION LOSS

10.00

8.00

6.00

HDFT/

FT/HD

4.00

2.00

0.00

SDT / SET065 - 080 FRICTION LOSS

5 8 12 16 20

GPM

Table 3C Pressure Drop Values SDT/SET065-119

SOLAR

COIL

BOILER

Table 3B Pressure Drop Chart SDT/SET119

Table 3B

Pressure Drop Chart SDT/SET119

COIL

FT/HD

12.00

10.00

8.00

6.00

4.00

2.00

5 8 12 16 20

GPM

SDT / SET119 FRICTION

LOSS

SOLAR

COIL

BOILER

COIL

MODEL

SDT065

SDT080

SDT119

SET065

SET080

SET119

Table 3C

Pressure Drop Values

PRESSURE DROP

COIL

CONN.

(IN)

COIL

LENGTH

(FT)

SQ FT

SURFACE

AREA

GPM8 GPM

SOLAR COIL

(FT / HD)

GPM16GPM20GPM

COIL

LENGTH

(FT)

SQ FT

SURFACE

AREA

GPM8 GPM

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

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

1 41.5 13.5 0.61 1.57 3.53 6.27 9.8

1 67.3 22.0 .73 1.87 4.22 7.5 11.71

PRESSURE DROP

BOILER COIL

(FT / HD)

GPM16GPM20GPM

SDT/SET Installation & Operation Manual

3 Boiler Side Piping (SDT models)

Figure 3-1 Piping Diagram Zoned with Circulators

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

HOT

WATER

OUT

SQUIRE

ZONE

ZONE CIRCULATORS

(TYPICAL)

ANTI-SCALD MIXING VALVE

COLD

WATER

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

PUMP

NOTICE

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.

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

SDT/SET

Installation & Operation Manual

3 Boiler Side Piping (SDT models) (continued)

Figure 3-2 Piping Diagram Zoned with Valves

ZONE #1

REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP WATER

DRAIN POINT

(TYPICAL)

BALL VALVE

(TYPICAL)

PRESSURE

SYSTEM SUPPLY

SENSOR

(WHEN USED)

AIR SEPARATOR

EXPANSION

TANK

UNION

(TYPICAL)

TEMPERATURE /

PRESSURE

GAUGE

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

SQUIRE

ZONE

HOT

WATER

OUT

ZONE

ZONE VALVES

(TYPICAL)

DIFFERENTIAL

PRESSURE

VALVE (IF USED)

ANTI-SCALD MIXING VALVE

COLD

WATER

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

PUMP

NOTICE

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.

Please note that the installer is responsible for ensuring DHW prioritization when piped as a zone.

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