Lochinvar TSU150 User manual

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.

2
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
WARNING
3
• 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.
4
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

5
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

6
1 General information
Figure 1-2 Thermal-Stor tappings
IMG00096
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
I
J
K
L
M
N
O
P
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.)
B
(in.)
C
(in.)
D
(in.)
E
(in.)
F
(in.)
G
(in.)
H
(in.)
I
(in.)
O
(in.)
P
(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
B
A
Figure 1-3 Spherical heat exchanger w/ tank
Table 1E
Tank with Spherical Measurements
Model Spherical
Model
A
(in.)
B
(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
7
Installation & Operation Manual

8
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

9
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
5
10
15
20
25
30
0 gpm 2 gpm 4 gpm 6 gpm 8 gpm 10 gpm 12 gpm 14 gpm
PRESSURE DROP, PSI
FLOW RATE, GPM
30
25
20
15
10
5
0
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)
1
GPM
2
GPM
4
GPM
6
GPM
8
GPM
10
GPM
12
GPM
14
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

10
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
T
TP
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