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.

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.

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

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)

1 General information

Figure 1-2 Thermal-Stor tappings

IMG00096

Installation & Operation Manual

Thermal-Stor Elements

Drain Valve

Auxiliary Heat Return

Low Temp Water Return

High Temp Water Return

Backup Heat Source Return

Space Heat Supply

Backup Heat Source Supply

Relief Valve / Air Vent

Auxiliary Heat Outlet

Heat Source Thermometer

Backup Heat Source Sensor

Sensor (Optional)

Solar Sensor

Spherical Exchanger, Inlet (Red Label)

Spherical Exchanger, Outlet (Blue Label)

Model

TSU150

TSU200

TSU257

TSU350

TSU423

TSU504

TSU650

TSU752

TSU940

Table 1D

Tapping Measurements (From Floor)

(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

(in.)

+ 14 hidden pages