Lochinvar SSS119, SSS041, SSS051, SSS031, SSS081 User Manual

Installation & Operation

Manual

Models: SSS031, SSS041,

SSS051, SSS081, & SSS119

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.

SSS-I&O Rev D

Installation & Operation Manual

Hazard definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Please read before proceeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. Pre-Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Boiler Side Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Domestic Side Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5. Start-up and Check-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

6. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17

Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Back Cover

Contents

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.

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

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.

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

Installation & Operation Manual

1 General Information

The Lochinvar SSS series indirect water heater (FIG. 1-1) is designed to generate domestic hot water in conjunction with a hot water boiler using forced boiler water circulation. This indirect water heater consists of a 444 Stainless Steel tank in which a smooth 304 stainless steel coil is located. Boiler water is pumped through the coil and heats the water in the tank. 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 444 Stainless Steel

Coil 304 Stainless Steel

Insulation (Top/Bottom) EPS Foam

Insulation Sides EPS Foam

Jacket Polypropylene

Hand Hole Cover Gasket Silicone “O” Ring

Operating Restrictions:

Maximum Allowable Tank Working Pressure - 150 psi

Design Hydrostatically Tested to 300 psi

Maximum Domestic Hot Water Temperature - 190°F

Maximum Boiler Water Temperature - 210°F

Figure 1-1 Lochinvar SSS Series Indirect Water Heater

Installation & Operation Manual

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

 WARNING

2 Pre-installation

1. The installation must conform with the instructions in this manual and all applicable local, state, provincial, and national codes, laws, regulations, and ordinances. Installations in Canada must conform to B149.1 or B149.2 Installation Codes.

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) 0.0 80.0

CAUTION

Locating the Tank

1. 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.

2. Locate the system in a location where a leak in the tank, the adjacent piping, or an open T & P valve will not damage the surrounding structure. If the area around the desired tank location is highly susceptible to water damage, install the tank in a pan with a drain.

3. The tank may be located some distance from the boiler provided the zone system is designed to provide the flow called for in Table 3A - Pressure Drop Values, through the coil. Also, 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 and servicing clearances must be figured when locating the water heater.

Installation & Operation Manual

Boiler Side Piping

Figures 3-1 thru 3-3 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 3A on page 6 are developed through the coil. This requires properly sized piping and a properly sized pump.

The system shown in FIG’s 3-1 thru 3-3 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 7 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. The circulator must be large enough to move boiler water through the coil regardless of the flow rate required through the heating zones.

3 Piping

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 coils. The recommended piping for a DHW priority system is depicted in FIG. 3-3 on page 8.

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 3A below. For example, if two tanks are to be manifolded together, the circulator and zone piping common to both tanks must be capable of moving 16 GPM (2 x 8 GPM), see FIG. 3-4 on page 9.

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 two different sizes in the same zone if their recovery is critical.

Table 3A

Pressure Drop Values

Model

Coil

Length (FT)

Tu b e

Diameter (IN)

Pressure Drop

(FT/HD)

8 GPM 12 GPM 16 GPM 20 GPM

SSS031 22.0 1 1/4 1.4 3.0 5.1 7.8

SSS041 27.6 1 1/4 1.7 4.0 6.4 9.8

SSS051 32.8 1 1/4 2.0 4.4 7.6 11.7

SSS081 49.2 1 1/4 N/A 6.3 10.9 16.7

SSS119 65.6 1 1/4 N/A N/A 15.3 23.5

+ 14 hidden pages