Lochinvar SHX40000 Installation Manual
CAUTION:
This appliance is not intended for potable water.
TSU-I-O Rev A
Installation & Operation
Manual
Models: TSU 150 - 940
WARNING
Save this manual for future reference.
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.
Contents
HAZARD DEFINITIONS .................................................... 2
PLEASE READ BEFORE PROCEEDING ........................ 3
1. GENERAL INFORMATION
Operating Restrictions ........................................................ 4
Tank Shipment................................................................... 4
Components .................................................................... 4-6
Spherical Heat Exchanger................................................. 7
2. PRE-INSTALLATION
Recommended Antifreeze Concentrations ........................ 8
Locating the Tank ............................................................... 8
Recommended Clearances ................................................ 8
3. SOLAR CONNECTIONS
Spherical Pressure Drop Calculations............................... 9
Piping Diagrams ............................................................... 10
4. HYDRONIC PIPING
Basic Hydronic Piping ...................................................... 11
Hydronic Heating Zoned with Circulators ......................... 11
Thermal-Stor Domestic Water Heating ............................ 11
Domestic Hot Water Priority ............................................. 11
High Output Piping ........................................................... 11
Relief Valves .................................................................... 12
Anti-Scald Mixing Valves .................................................. 13
Piping Diagrams........................................................... 14-16
5. STARTUP AND MAINTENANCE
System Startup ................................................................. 17
Maintenance Schedule ................................................ 17-18
Winterizing the System ............................................... 18
To Drain/Flush the System ......................................... 18
NOTES ............................................................................. 19
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.
2
Please read before proceeding
Installation & Operation Manual
WARNING
NOTICE
WARNING
Installer – Read all instructions before
installing. Perform steps in the order given.
Have this storage tank 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 model and serial number
from the tank 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.
• Installation and service must be performed by a
qualified installer, service agency, or the gas supplier.
WARNING
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
When servicing the Thermal-Stor –
• To avoid severe burns, allow the appliance to cool
before performing maintenance.
Appliance operation –
• 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.
CAUTION
This appliance is not intended for potable
water.
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.
3
Installation & Operation Manual
1 General information
The Lochinvar Thermal-Stor stratified solar tank is designed to use a solar thermal collector system, in conjunction with a
back-up heat source, to provide water for a closed loop hydronic heating system. The appliance consists of a spherical heat
exchanger connected to an unlined storage tank. The Thermal-Stor tank uses solar heated water pumped through the spherical
heat exchanger to heat water in the tank. A backup heat source is used to maintain the desired tank temperature in the event that
adequate solar heat is not available. Tank components and specifications are detailed in FIG.’s 1-1 and 1-2, as well as in Tables
1A - 1D on pages 4 through 6.
The Thermal-Stor buffer tank can provide both thermal storage volume and hydraulic separation between the boiler or heat
pump and the building distribution system. The primary application of a buffer tank is to reduce boiler or heat pump cycling
in systems operating below design load conditions, or in systems having several low Btu heat loads calling for heat at different
times. The solar-assisted buffer tank provides thermal storage volume which can help reduce short-cycling, leading to longer
runtimes, higher efficiency and longer equipment life for the solar thermal system and heat source. If piped correctly, the buffer
tank can also function as a hydraulic separator, effectively separating the flow in the boiler loop from the flow in the distribution
system (FIG.’s 4-2 and 4-3, on pages 14 and 15). This tank has many applications including geothermal, pool and space heating.
Consult the factory if your specific application is not covered in this manual. This tank is not intended for use in gravity water
heating applications.
Operating Restrictions:
• Maximum stored water temperature is 210°F.
• Maximum working pressure for the vessel is 125 psig.
Tank shipment
Tanks taller than 7.5 feet will be shipped horizontally. Four
shipping legs are used to secure the tank to a pallet, and holes
are provided in the top cover for access to lifting lugs. The
shipping legs should be removed when the tank is removed
from the shipping crate.
Use field-supplied insulation to pack the shipping and lug
compartments, then use the factory provided covers to
conceal compartments upon final installation.
Table 1A
Thermal-Stor
Tank Component Materials
Component Material
Tank Steel SA414-G
Insulation Polyurethane Foam
Jacket Pre-paint Sheet Metal
Table 1B
Spherical Heat Exchanger
Component Materials
Component Material
Housing Steel S 235 JR
Heat Exchanger Coil Copper
Insulation Polyurethane Foam
Jacket Polypropylene
4
1 General information (continued)
Figure 1-1 Thermal-Stor solar stratified tank components
TEMPERATURE
GAUGE
Installation & Operation Manual
AUXILIARY
HEAT OUTLET
BACKUP
HEAT SOURCE
SENSOR
SPHERICAL
HEAT EXCHANGER
SOLAR
SENSOR
IMG00104
BACKUP
HEAT SOURCE
INLET
BACKUP
HEAT SOURCE
RETURN
AUXILIARY
HEAT INLET
Table 1C
Thermal-Stor Tank Specifications
Boiler
Supply/
Return
(NPT)
Model
Tank
Diameter
(in.)
Jacket
Diameter
(in.)
Hydronic
Tappings
(NPT)
TSU150 24 28 2" 2" 140 1775
TSU200 28 32 2" 2" 190 2300
TSU257 30 34 2" 2" 240 2875
TSU350 36 40 2" 2" 340 3775
TSU423 36 40 2" 2" 420 4650
TSU504 42 46 2" 2" 495 5475
TSU650 48 52 2" 2" 645 7050
TSU752 48 52 2" 2" 745 8100
TSU940 48 52 2" 2" 920 10000
Tank
Water
Volume
(gal.)
Full
Weight
(lbs)
5
1 General information
Figure 1-2 Thermal-Stor tappings
I
I
J
J
K
K
L
L
M
M
N
N
P
O
O
IMG00096
Installation & Operation Manual
H
G
F
E
D
C
B
A
Thermal-Stor Elements
A
Drain Valve
B
Auxiliary Heat Return
C
Low Temp Water Return
D
High Temp Water Return
E
Backup Heat Source Return
F
Space Heat Supply
G
Backup Heat Source Supply
H
Relief Valve / Air Vent
I
Auxiliary Heat Outlet
J
Heat Source Thermometer
K
Backup Heat Source Sensor
L
Sensor (Optional)
M
Sensor (Optional)
N
Solar Sensor
O
Spherical Exchanger, Inlet (Red Label)
P
Spherical Exchanger, Outlet (Blue Label)
Model
TSU150
TSU200
TSU257
TSU350
TSU423
TSU504
TSU650
TSU752
TSU940
Table 1D
Tapping Measurements (From Floor)
A
(in.)
2 1/4 10 3/4 21 1/4 28 3/4 33 50 1/4 55 1/4 71 75 3/4 3 1/2 3 1/2
2 1/4 11 1/4 22 3/4 33 38 1/2 55 1/2 60 1/2 76 80 4 1/4 4 1/4
2 1/4 15 1/2 34 1/2 42 1/2 49 62 3/4 67 3/4 87 91 3/4 8 1/2 8 1/2
3 1/4 17 36 3/4 46 1/2 52 3/4 61 1/4 66 1/4 87 1/4 91 1/4 10 10
3 1/4 17 40 1/4 52 58 1/4 75 3/4 80 3/4 100 104 10 10
2 1/2 18 1/2 33 1/2 42 1/4 49 59 3/4 64 3/4 87 91 1/2 11 1/2 11 1/2
2 1/4 20 1/2 36 3/4 44 1/2 51 60 3/4 65 3/4 88 93 13 1/2 13 1/2
2 20 1/2 38 1/4 50 57 1/2 70 75 100 104 3/4 10 1/2 10 1/2
2 1/4 20 1/2 49 63 70 1/2 88 1/2 93 1/2 124 129 13 1/2 13 1/2
B
(in.)
C
(in.)
D
(in.)
E
(in.)
F
(in.)
G
(in.)
H
(in.)
I
(in.)
O
(in.)
P
(in.)
6
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