BTC SST150-40, SST250-65, SST300-80, SST450-119 Installation And Operating Manual
Indirect Fired Water Heaters
Installation and Operating Manual
Models: SST150-40
SST250-65
SST300-80
SST450-119
CAUTION
The heat transfer medium must be water or other nontoxic fl uid
having a toxicity rating or class of 1, as listed in Clinical
Toxicology of Commercial Products, 5th edition.
The pressure of the heat transfer medium must be limited to a
maximum of 30 PSIG by an approved safety or relief valve.
®
C
US
DANGER
This manual must only be used by a trained 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.
Installation & Operating Manual
2 |
Indirect Fired Water Heaters Installation and Operating Manual
Table of Contents
1 General Information 6
2 Pre-installation 7
3 Boiler Side Piping 8
4 Domestic Side (Tank) Piping 13
5 Wiring 17
Installation & Operating Manual
6 Start-up and Check-out 18
7 Maintenance 19
8 Performance Data 21
Indirect Fired Water Heaters Installation and Operating Manual
| 3
Installation & Operating Manual
Explanation Of Symbols
Key To Symbols
Warnings
Warnings in this document are identifi ed by a
warning triangle printed against a grey
background.
Keywords at the start of a warning indicate
the type and seriousness of the ensuing risk if
measures to prevent the risk are not taken.
The following keywords are defi ned and can be used in
this document:
NOTICE indicates that damage to property may occur.
CAUTION indicates that personal injury may occur.
WARNING indicates that severe personal injury may
occur.
DANGER indicates that severe personal injury or
death may occur.
Important information
Please Read Before Proceeding
DANGER: Installer – Read all instructions
before installing.
Perform steps in the order given. Have this
indirect water heater serviced/inspected
by a qualifi ed service technician, at least
annually. Failure to comply with the above
could result in severe personal injury, death
or substantial property damage.
NOTICE:
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 fi led immediately
against the transportation company by
the consignee.
– Factory warranty does not apply to
appliances improperly installed or
improperly operated.
Important information in cases where there is no
risk of personal injury or material losses is
identifi ed by the symbol shown on the left. It is
bordered by horizontal lines above and below the
text.
DANGER:
If the information in this manual is not
followed exactly, a fi re 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 fl ammable 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 home/building.
– Evacuate the home/building immediately.
– Immediately call your gas supplier. Follow
the gas supplier’s instructions.
– If you cannot reach your gas supplier, call
the fi re department.
– Installation and service must be
performed by a qualifi ed installer, service
agency, or the gas supplier.
4 |
Indirect Fired Water Heaters Installation and Operating Manual
Installation & Operating Manual
DANGER: 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 infi rm 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
fi ts 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 fl ow away from any person
Protection Must Be Taken Against Excessive
Temperature and Pressure! Installation of a
Temperature & Pressure (T&P) relief valve is
required.
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 fl ooded 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 ½ 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 ½ seconds
155° F About 1 second
DANGER:
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
Indirect Fired Water Heaters Installation and Operating Manual
| 5
Installation & Operating Manual
1 General Information
The SST 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 316L Stainless Steel
tank in which a smooth 304L stainless steel coil is located
(Table 1A). 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 fl uid
other than water. It is also not intended for use in gravity
hot water heating systems.
Operating Restrictions:
• Maximum domestic hot water temperature is 194°F.
• Maximum boiler water temperature is 210°F.
• Maximum working pressure for the vessel tank is 150
psig.
Component Materials Table 1A
Component Material
Tank 316L Steel Stainless Steel
Coil 304L Stainless Steel
Insulation Polyurethane
Jacket Polypropylene/ABS
Single-Wall Heat Exchanger
National Standard Plumbing Code
Single-wall heat exchangers in water heaters comply with
the National Standard Plumbing Code provided that:
• boiler water (including additives) is practically non-toxic,
having a toxicity rating or class of 1, as listed in Clinical
Toxicology of Commercial Products, and
• boiler water pressure is limited to a maximum of 30 psig
by approved relief valve.
Uniform Plumbing Code
Single-wall heat exchangers are permitted if they satisfy all
of the following requirements:
1. The heat transfer medium is potable water or contains
only substances which are recognized as safe by the
U.S. Food and Drug Administration.
2. The pressure of the heat transfer medium is maintained
less than the normal minimum operating pressure of the
potable water system.
3. The equipment is permanently labeled to indicate that
only additives recognized as safe by the FDA shall be
used in the heat transfer medium.
Other heat exchanger designs may be permitted where
approved by local code.
Figure 1-1
“F”
PART NO.
SST150-40
SST250-65
SST300-80
SS T450-119
NOTES:
22.5°
45°
1-1/2” NPT (SEE NOTE 1)
“E”
“D”
“C”
“B”
“A”
1. 1” NPT ON SST150-40.
2
1
3/4” NPT
3
1” NPT
AQUASTAT/SENSOR WELL
4
1” NPT
1-1/2” NPT (SEE NOTE 1)
“A”
(in.)
3
3 1/4
3 1/4
3 1/4
5
“B”
(in.)
8 1/4
9 1/4
9 1/4
9 1/4
SST150 - SST450
25 1/4
31 3/4
“D”
“C”
(in.)
(in.)
48 1/2
28
52 1/2
28
61 3/4
60 1/4
1. RELIEF VALVE CONNECTION
2. HOT WATER OUTLET
3. BOILER WATER IN
4. BOILER WATER OUT
5. DRAIN/COLD WATER INLET
“E”
(in.)
56
60
70
69
WEIGHT
“F”
FULL OF WATER
(in.)
(lbs.)
20
24
24
28
515
820
921
1268
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Indirect Fired Water Heaters Installation and Operating Manual
Installation & Operating 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. 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 qualifi ed
water treatment expert should be consulted.
CAUTION:
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.
Water Chemistry Requirements Table 2A
Water used in the tank must have characteristics falling
within the following limits:
Characteristic Min. Max.
Ph 6.0 8.0
Locating the Tank
1. Choose a location for your water heater centralized to
the piping system. You must also locate the SST water
heater where it will not be exposed to freezing
temperatures. Additionally, you will need to place the
water heater so that the controls, drain, and inlet/
outlets are easily accessible. This appliance must not be
installed outdoors, as it is certifi ed as an indoor
appliance, and must also be kept vertical on a level
surface.
2. Keep distance between boiler and water heater to a
minimum to:
a. reduce piping heat loss
b. provide minimal friction loss
3. Figure 1-1 on page 6 shows the weights of all the tanks
fi lled with water. Make sure that the location chosen for
the tank is capable of supporting it.
CAUTION:
This appliance must be placed where
leakage from the temperature and pressure
(T&P) 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 fl oors of
the building. A water heater should always
be located in an area with a fl oor drain or
installed in a drain pan suitable for water
heaters. The manufacturer shall not be held
liable for any such water damage. Damage
caused by the failure to properly install a
drain pan or in an area with a drain is not
the responsibility of the manufacturer or
Bosch Thermotechnology Corp. (BTC)..
Chloride (PPM) -- 80
Indirect Fired Water Heaters Installation and Operating Manual
4. The tank may be located some distance from the boiler
provided the pump is designed to provide the fl ow
called for in Table 3B - 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.
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 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 fi gured when locating the water
heater.
| 7
Installation & Operating Manual
0581216
20
3 Boiler Side Piping
Figures 3-1 thru 3-4 show typical boiler side piping for
several common situations. Regardless of which system is
used it is imperative that the fl ow rates called for in Table
3B are developed through the coil. This requires properly
sized piping and a properly sized pump. The system shown
in FIG’s 3-1 thru 3-4 are described below:
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
controller will shut off the boiler circulator and activate
the domestic hot water circulator. Once the DHW demand
is satisfi ed, 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. 3-1 and 3-2 using a GB142 wall hung
boiler.
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 3-3 illustrates typical circulator zone piping
with a fl oor standing G115WS, G125BE, GB125BE, or
G215 boiler.
Multiple Tank Connections (Boiler Side)
Multiple tank installations must be done in the “reversereturn” manner. The reason for this is to create the same
pressure drop (and therefore, the same fl ow) through the
coil of each tank. The boiler manifold piping must be sized
so that each coil has the fl ow rate called for in Table 3B.
Because the pressure drop through tank coils varies from
size to size, it is hard to predict the fl ow 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 different sizes in the same zone if
their recovery is critical. A sample system is shown in FIG.
3-4.
Pressure Drop Chart Table 3A
12
10
8
6
Head Loss (Ft. of Hd.)
4
2
SST450-119
SST250-65/
SST300-80
SST150-40
0
.
Flow Rate
Pressure Drop Values Table 3B
Pressure Drop (FT/HD)
Surface
area
(SQ-FT)
5
GPM8 GPM
12
GPM
16
GPM
GPM
Model
Water
Inlet
(IN)
Water
Outlet
(IN)
Coil
Connection
(IN)
Coil
Length
(FT)
SST150-40 1 1 1 30.8 10.0 0.41 1.04 2.34 4.16 6.49
SST250-65 1.5 1.5 1 41.5 13.5 0.61 1.57 3.53 6.27 9.80
SST300-80 1.5 1.5 1 41.5 13.5 0.61 1.57 3.53 6.27 9.80
SST450-119 1.5 1.5 1 67.3 22.0 0.73 1.87 4.22 7.50 11.71
20
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Indirect Fired Water Heaters Installation and Operating Manual
AIR
SEPARATOR
AIR
SEPARATOR
DHW
TANK
PUMP
GB 142
BOILER
Installation & Operating Manual
HOT
WATER
ANTI-SCALD
MIXING VALVE
OUT
COLD
WATER
IN
PRESSURE RELIEF
VALVE
TANK SENSOR
TO
SYSTEM
BALL VALVE
(TYPICAL)
SYSTEM
PUMP
EXPANSION
TANK
DRAIN
POINT
FROM
SYSTEM
Y-STRAINER
(RECOMMENDED)
Figure 3-1 GB142 Boiler Low Loss Header piping and DHW priority
NOTICE:
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.
SST series tank
CHECK VALVE
RECIRCULATION
DRAIN
( FIELD SUPPLY )
PUMP
Indirect Fired Water Heaters Installation and Operating Manual
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