Lochinvar STU150 Installation Manual

STU-I-O Rev A

Installation & Operation

Manual

Models: STU150 - 940

 WARNING

Save this manual for future reference.

IMG00044

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

Locating the Tank ............................................................... 8

Recommended Clearances ................................................ 8

3. SOLAR CONNECTIONS

Spherical Pressure Drop Calculations............................... 9

Piping Diagrams ............................................................... 10

4. DOMESTIC SIDE PIPING

Basic Domestic Piping ..................................................... 11

Domestic Water Piping for Distant Fixtures ..................... 11

Recirculation Lance .......................................................... 12

Recirculation Lance Pressure Drop Chart ....................... 12

Direct Piping to Cold Water Inlet ...................................... 13

Multiple Tank Domestic Water Piping .............................. 13

Anti-Scald Mixing Valves ...................................................13

Domestic Coil Pressure Drop Chart................................ 14

Temperature and Pressure (T&P) Relief Valve .......... 15-16

Table 4E - Minimum Relief Valve (ASME Rating) 15

Piping Diagrams........................................................... 17-19

5. BOILER SIDE PIPING

Multiple Tank Connections ............................................... 20

Piping Diagrams ........................................................ 20 - 21

6. STARTUP AND MAINTENANCE

System Startup ................................................................. 22

Maintenance Schedule ................................................ 22-23

Winterizing the System ............................................... 23

To Drain/Flush the System ......................................... 23

7. PERFORMANCE DATA

Performance Data Charts ........................................... 24-27

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

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.

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

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

When servicing the Strato-Therm+ –

• 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.

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

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.

Installation & Operation Manual

1 General information

The Lochinvar Strato-Therm+ solar stratified tank (FIG. 1-1, page 5) is designed to use a solar collector system, in conjunction with a back-up heat source, to generate domestic hot water. This solar tank consists of a spherical heat exchanger attached to an unlined tank containing a corrugated 316L stainless steel coil. Tank components and specifications are detailed in FIG.’s 1-1 and 1-2 (pages 5 and 6), as well as Tables 1A - 1D.

Solar heated water is pumped through the spherical heat exchanger to heat the water in the tank. A backup heat source is used to maintain desired tank temperature in the event that solar heated water is not available. The tank may be used to heat domestic potable water which runs through the stainless steel coil. In addition to generating domestic hot water, this tank can have many other applications including indirect pool heating and space heating. Consult the factory if your specific application is not covered in this manual. The tank is not intended for use in gravity water heating applications.

Operating Restrictions:

• Maximum domestic hot water temperature is 194°F.

• Maximum boiler 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

Strato-Therm+

Tank Component Materials

Component Material

Tank Steel SA414-G

Coil 316L Stainless Steel

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 Strato-Therm+ solar stratified tank components

HEAT SOURCE

THERMOMETER

BACKUP HEAT

SOURCE SENSOR

SPHERICAL

HEAT EXCHANGER

Installation & Operation Manual

DOMESTIC WATER OUTLET

DOMESTIC WATER

STAINLESS STEEL COIL

BACKUP

HEAT SOURCE

SUPPLY

BACKUP

HEAT SOURCE

SOLAR

SENSOR

IMG00078

RETURN

DOMESTIC

WATER

INLET

Table 1C

Strato-Therm+ Tank and Coil Specifications

Stainless

Steel

Coil

Surface

Area (ft2)

Tank

Water

Volume

(gal.)

Domestic

Water

Volume

(gal.)

Full

Weight

(lbs)

Model

Tank

Diameter

(in.)

Jacket

Diameter

(in.)

Domestic

Water

Inlet/ Outlet (NPT)

Boiler

Supply/

Return

(NPT)

Stainless

Steel

Coil

Length

(ft.)

STU150 24 28 1" 2" 82 69 125 12.0 1715

STU200 28 32 1" 2" 98 83 175 14.5 2300

STU257 30 34 1" 2" 98 83 225 14.5 2875

STU350 36 40 1" 2" 98 83 325 14.5 3775

STU423 36 40 1" 2" 115 97 400 16.0 4650

STU504 42 46 1" 2" 121 103 475 17.0 5475

STU650 48 52 1" 2" 131 111 625 20.0 7050

STU752 48 52 1" 2" 131 111 725 20.0 8100

STU940 48 52 1" 2" 131 111 900 20.0 10000

1 General information

Figure 1-2 Strato-Therm+ tappings

Installation & Operation Manual

IMG00088

Strato-Therm+ Elements

Drain Valve

Domest Water Inlet

Low Temp Water Return

High Temp Water Return

Backup Heat Source Return

Space Heat Supply

Backup Heat Source Supply

Relief Valve / Air Vent

Domestic Hot Water Outlet

Heat Source Thermometer

Backup Heat Source Sensor

Sensor (Optional)

Solar Sensor

Spherical Exchanger, Inlet (Red Label)

Spherical Exchanger, Outlet (Blue Label)

Model

STU150

STU200

STU257

STU350

STU423

STU504

STU650

STU752

STU940

Table 1D

Tapping Measurements

(in.)

2 1/4 12 1/4 21 1/4 28 3/4 33 50 3/4 55 1/4 71 76 3/4 3 1/2 3 1/2

3 1/2 12 3/4 22 3/4 33 38 1/2 55 1/4 59 1/2 76 80 1/4 4 1/4 4 1/4

2 1/4 17 34 1/2 42 1/2 49 63 1/2 67 3/4 87 92 3/4 8 1/2 8 1/2

3 1/4 18 3/4 37 46 1/2 53 62 66 1/4 87 1/4 92 1/4 10 10

3 1/4 18 1/2 40 1/4 52 58 1/4 76 1/2 80 3/4 100 105 1/4 10 10

2 1/2 19 1/2 33 1/2 42 1/4 49 60 1/4 64 3/4 87 92 1/2 11 1/2 11 1/2

2 21 1/2 36 3/4 44 1/2 51 61 1/4 65 3/4 88 94 13 1/2 13 1/2

2 22 38 1/4 50 57 1/2 70 3/4 75 100 105 3/4 10 1/2 10 1/2

2 22 49 63 70 1/2 89 93 1/2 124 130 13 1/2 13 1/2

(in.)

1 General information (continued)

Installation & Operation Manual

Spherical heat exchanger

The Strato-Therm+ uses a copper finned tube spherical heat exchanger to provide optimum solar stratified charging. The spherical exchanger helps maintain optimal use of solar energy for hot water and space heating. The multi-functional design improves efficiency in every system. Insulated with polyurethane foam, the spherical heat exchanger and tank maintain a space-saving design with minimal heat loss. Refer to FIG. 1-3 and Tables 1E and 1F for additional spherical heat exchanger information and measurements.

Figure 1-3 Spherical heat exchanger w/ tank

Table 1E

Tank with Spherical Measurements

Model

STU150 SHX40000 44 1/2 28

STU200 SHX40000 48 1/4 32

STU257 SHX40001 50 1/4 34

STU350 SHX40001 56 1/4 40

STU423 SHX40002 56 1/4 40

STU504 SHX40002 62 1/4 46

STU650 SHX40003 71 1/4 52

STU752 SHX40003 71 1/4 52

STU940 SHX40004 71 1/4 52

Spherical

Model

(in.)

IMG00054

Table 1F

Spherical Heat Exchanger Specifications

Tank

Model

SHX40000 8 1/2 14 61 0.75" 28 0.55 7.9 8.45

SHX40001 8 1/2 14 61 0.75" 42 0.65 7.8 8.45

SHX40002 8 1/2 14 61 1" 59 1.1 7.35 8.45

SHX40003 11 3/4 17 61 1.25" 102 2.0 15.8 17.8

SHX40004 11 3/4 17 80 1.25" 102 2.0 15.8 17.8

Diameter

(in)

Jacket

Diameter

(in)

Jacket

Height

(in)

Solar

Inlet

Return

(NPT)

HEX

Surface

Area

(ft2)

HEX

Water

Volume

(gal)

Tank

Water

Volume

(gal)

Total

Water

Volume

(gal)

2 Pre-installation

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. Ensure that the domestic water supply to the stainless steel coil 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 site, 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 domestic water coil due to corrosion. Damage in such cases is not covered under warranty.

Table 2A

Water Chemistry Requirements

Domestic potable water must have characteristics falling within the following limits:

Characteristic Min. Max.

pH 6.5 9.5

Chloride (PPM) -- 200

Locating the Tank

1. Choose a location for the Strato-Therm+ centralized to the piping system. You must also locate the Strato-Therm+ where it will not be exposed to freezing temperatures. Additionally, you will need to place the appliance 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. Table 1C on page 5 shows the weight of all the tanks filled with water. Ensure that the location chosen for the tank is capable of supporting the weight.

CAUTION

3. The tank may be located some distance from the heat source provided that the pump is designed to to provide enough flow for both units to perform properly. The further the distance from the tank to the heat source, the longer the response time will be to provide sufficient heat to the tank. Insulate piping between the heat source and the tank.

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.

 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 appliance. A 12-inch vertical clearance is recommended from the top of the appliance. A zero clearance is allowed for the sides of the appliance. However, boiler and servicing clearances must be figured when locating the appliance.

02468101214

Pressure Drop, psi

Flow Rate, gpm

STU150

STU200 / SHX40000

STU257

STU350 / SHX40001

STU423

STU504 / SHX40002

STU650

STU752 / SHX40003

STU940 /

SHX40004

Installation & Operation Manual

3 Solar connections

A solar thermal system consists of several components selected to work together to convert solar energy into hot water for various applications. A controller is used to turn on a pump when the fluid in the solar collectors is warmer than the water in the StratoTherm+ tank. The pump will transport hot fluid from the collector to the heat exchanger and replace it with cooler fluid returning. The collectors, pump station and heat exchanger are connected with supply and return piping that is insulated to minimize heat losses (FIG. 3-1, page 10). The system is equipped with over-temperature and over-pressure devices that prevent unsafe operating conditions. When multiple heat exchangers are used, they should connected in reverse-return arrangement (FIG. 3-2, page 10). This will help ensure that solar heated water is distributed evenly between the heat exchangers. Pressure drop and maximum operating values for the Strato-Therm+ spherical heat exchanger are listed in Tables 3A - 3C.

Installation and commissioning must be carried out by a licensed contractor. Take appropriate safety measures when carrying out any installation work on the roof and observe all relevant accident prevention regulations. It is the installer’s responsibility to comply with the building and installation codes in effect and all regulations that apply to the operation of a solar hot water system.

MODEL

STU150

STU200

STU257

STU350

STU423

STU504

STU650

STU752

STU940

Table 3A

Spherical Heat Exchanger

Pressure Drop Values

PRESSURE DROP PSI)

SPHERICAL

MODEL

SHX40000 0.20 0.68 2.29 4.66 7.71 11.39 15.67 20.52

SHX40001 0.24 0.81 2.71 5.52 9.13 13.49 18.56 24.31

SHX40002 0.07 0.23 0.78 1.59 2.64 3.90 5.36 7.02

SHX40003 0.03 0.09 0.30 0.61 1.01 1.50 2.06 2.70

SHX40004 0.03 0.09 0.30 0.61 1.01 1.50 2.06 2.70

GPM2 GPM4GPM6GPM8GPM10GPM12GPM14GPM

Table 3C

Spherical Heat Exchanger Pressure Drop Chart

Table 3B

Spherical Maximum Operating

Conditions

Copper Heat

Exchanger

Temperature 230°F 230°F

Pressure 145 psi 125 psi

Tank

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