Lochinvar TSU150 Bedienungsanleitung

Installation & Operation

Manual

Models: TSU 150 - 940

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.

TSU-I-O Rev A

CAUTION:

This appliance is not intended for potable water.

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.

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

Contents

Please read before proceeding

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.

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.

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.

WARNING

NOTICE

WARNING

• Installation and service must be performed by a

qualified installer, service agency, or the gas supplier.

Installation & Operation Manual

CAUTION This appliance is not intended for potable

water.

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.

Table 1A

Thermal-Stor

Tank Component Materials

Component Material

Tank Steel SA414-G

Insulation Polyurethane Foam

Jacket Pre-paint Sheet Metal

Operating Restrictions:

• Maximum stored water temperature is 210°F.

• Maximum working pressure for the vessel is 125 psig.

Table 1B

Spherical Heat Exchanger

Component Materials

Component Material

Housing Steel S 235 JR

Heat Exchanger Coil Copper

Insulation Polyurethane Foam

Jacket Polypropylene

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.

Installation & Operation Manual

1 General information (continued)

Table 1C

Thermal-Stor Tank Specifications

Model

Tank

Diameter

(in.)

Jacket

Diameter

(in.)

Hydronic

Tappings

(NPT)

Boiler

Supply/

Return

(NPT)

Tank

Water

Volume

(gal.)

Full

Weight

(lbs)

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

AUXILIARY

HEAT OUTLET

BACKUP

HEAT SOURCE

INLET

BACKUP

HEAT SOURCE

RETURN

TEMPERATURE

GAUGE

SPHERICAL

HEAT EXCHANGER

BACKUP

HEAT SOURCE

SENSOR

SOLAR

SENSOR

IMG00104

AUXILIARY

HEAT INLET

Figure 1-1 Thermal-Stor solar stratified tank components

Installation & Operation Manual

1 General information

Figure 1-2 Thermal-Stor tappings

IMG00096

Thermal-Stor Elements

ADrain Valve

BAuxiliary Heat Return

CLow Temp Water Return

D High Temp Water Return

EBackup Heat Source Return

FSpace Heat Supply

GBackup Heat Source Supply

HRelief Valve / Air Vent

IAuxiliary Heat Outlet

JHeat Source Thermometer

KBackup Heat Source Sensor

LSensor (Optional)

MSensor (Optional)

NSolar Sensor

OSpherical Exchanger, Inlet (Red Label)

PSpherical Exchanger, Outlet (Blue Label)

Table 1D

Tapping Measurements (From Floor)

Model A

(in.)

TSU150 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

TSU200 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

TSU257 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

TSU350 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

TSU423 3 1/4 17 40 1/4 52 58 1/4 75 3/4 80 3/4 100 104 10 10

TSU504 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

TSU650 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

TSU752 2 20 1/2 38 1/4 50 57 1/2 70 75 100 104 3/4 10 1/2 10 1/2

TSU940 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

Installation & Operation Manual

1 General information (continued)

Spherical heat exchanger

The Thermal-Stor 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 hydronic 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.

IMG00107

Figure 1-3 Spherical heat exchanger w/ tank

Table 1E

Tank with Spherical Measurements

Model Spherical

Model

(in.)

TSU150 SHX40000 44 1/2 28

TSU200 SHX40000 48 1/4 32

TSU257 SHX40001 50 1/4 34

TSU350 SHX40001 56 1/4 40

TSU423 SHX40002 56 1/4 40

TSU504 SHX40002 62 1/4 46

TSU650 SHX40003 71 1/4 52

TSU752 SHX40003 71 1/4 52

TSU940 SHX40004 71 1/4 52

Table 1F

Spherical Heat Exchanger Specifications

Model

Tank

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)

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

Installation & Operation Manual

2 Pre-installation

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. If the heat source water contains antifreeze, a maximum

50/50 mixture of inhibitedpropyleneglycolisrecommended.

The heat source water, including additives, must be

non-toxic, having a toxicity rating or class of 1, as listed in

the Clinical Toxicology of Commercial Products.

3. Read and understand all installation requirements in

this manual.

Table 2A

Recommended Antifreeze Concentrations

Glycol Freeze

Protection Percentage Freeze

Protection

Propylene Glycol

Only

20 18°F

30 8°F

40 -6°F

50 -28°F

Locating the Tank

1. Choose a location for the Thermal-Stor centralized to

the piping system. You must also locate the Thermal-Stor

where it will not be exposed to freezing temperatures.

Additionally, you will need to place the tank so that

the controls, drain, and inlet/outlets are easily accessible.

This tank must not be installed outdoors, as it is

certified as an indoor appliance, and must 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.

This tank 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 tank should always

be located in an area with a floor drain or

installed in a drain pan suitable for tanks.

Lochinvar shall not be held liable for any

such water damage.

CAUTION

Failure to properly support the tank could

result in property damage or personal

injury.

WARNING

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.

3. The tank may be located some distance from the heat

source provided that the pump is designed 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.

WARNING Do not use automotive, ethylene glycol or

petroleum-based antifreeze. Do not use

any undiluted antifreeze. This can cause

severe personal injury, death, or substantial

property damage.

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

Thermal-Stor tank plus the differential. 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 should be connected with supply and return piping

that is insulated to minimize heat losses (FIG. 3-1, page 10). The system should be equipped with over-temperature and over-

pressure devices that prevent unsafe operating conditions. When multiple Thermal-Stor tanks are used, they should be 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 Thermal-Stor 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.

Table 3B

Spherical Maximum Operating

Conditions

Copper Heat

Exchanger

Tank

Temperature 230°F 230°F

Pressure 145 psi 125 psi

Table 3C

Spherical Heat Exchanger Pressure Drop Chart

TSU150-200 /

SHX40000

TSU257-350 /

SHX40001

TSU423-504 /

SHX40002

TSU650-940 /

SHX40003

SHX40004

0 gpm 2 gpm 4 gpm 6 gpm 8 gpm 10 gpm 12 gpm 14 gpm

PRESSURE DROP, PSI

FLOW RATE, GPM

02468101214

TSU257-350/

SHX40001

TSU150-200/

SHX40000

TSU423-504/

SHX40002

TSU650-940/

SHX40003

SHX40004

Table 3A

Spherical Heat Exchanger

Pressure Drop Values

MODEL SPHERICAL

MODEL

PRESSURE DROP PSI)

GPM

TSU150 SHX40000 0.20 0.68 2.29 4.66 7.71 11.39 15.67 20.52

TSU200

TSU257 SHX40001 0.24 0.81 2.71 5.52 9.13 13.49 18.56 24.31

TSU350

TSU423 SHX40002 0.07 0.23 0.78 1.59 2.64 3.90 5.36 7.02

TSU504

TSU650 SHX40003 0.03 0.09 0.30 0.61 1.01 1.50 2.06 2.70

TSU752

TSU940 SHX40004 0.03 0.09 0.30 0.61 1.01 1.50 2.06 2.70

Installation & Operation Manual

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.

NOTICE

Figure 3-1 Solar System Piping

3 Solar connections





SOLAR

COLLECTOR

SOLAR AIR

RELEASE VENT

(OPTIONAL)

SOLAR PUMP STATION /

CONTROLLER

TEMPERATURE GAUGE

(TYPICAL)

SPHERICAL

HEAT EXCHANGER

SOLAR

SENSOR

FILL AND

FLUSH VALVE

PRESSURE

RELIEF VALVE

IMG00095

TEMPERATURE

GAUGE

EXPANSION

TANK

Figure 3-2 Solar System Piping with Multiple Heat Exchangers

SOLAR

COLLECTOR

SOLAR AIR

RELEASE VENT

(OPTIONAL)

TEMPERATURE

GAUGE

(TYPICAL)

SPHERICAL

HEAT EXCHANGER

SOLAR

SENSOR

PRESSURE

RELIEF VALVE

IMG00108

TEMPERATURE

GAUGE

EXPANSION

TANK

SOLAR

PUMP STATION /

CONTROLLER

Installation & Operation Manual

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