HTP GL-50, GL-175, GL-80, GL-119 User Manual

Installation

Start-Up

Maintenance

Parts

S

uperstor

Glass Lined

Storage Tanks

Warranty

For Residential and
Commercial Use

GL Models*

*Available in Metal Jacketed ASME and Non-ASME Models

The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as
required by the Safe Drinking Water Act, Section 1417.

This manual must only be used by a qualied installer / service technician. Read all instructions in this manual before
installing. Perform steps in the given order. Failure to do so could result in substantial property damage, severe
personal injury, or death.

HTP reserves the right to make product changes or updates without notice and will not be held liable for
typographical errors in literature.

NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.

120 Braley Road P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com

lp-181 Rev. 3.3.15

2

The following dened terms are used throughout this manual
to bring attention to the presence of hazards of various risk
levels or to important product information.

DANGER indicates an imminently hazardous situation which,
if not avoided, will result in serious personal injury or death.

WARNING indicates a potentially hazardous situation which, if
not avoided, could result in personal injury or death.

CAUTION indicates a potentially hazardous situation which, if
not avoided, may result in moderate or minor personal injury.

CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided, may
result in property damage.

NOTICE is used to address practices not related to personal
injury.

Foreword

This manual is intended to be used in conjunction with other
literature provided with the storage tank. This includes all
related control information. It is important that this manual,
all other documents included in this system, and additional
publications including the Code for the Installation of Heat
Producing Appliances (latest version), be reviewed in their
entirety before beginning any work.

Installation should be made in accordance with the regulations
of the Authority Having Jurisdiction, local code authorities, and
utility companies which pertain to this type of water heating
equipment.

Authority Having Jurisdiction (AHJ) – The AHJ may be a federal,
state, local government, or individual such as a re chief, re
marshal, chief of a re prevention bureau, labor department
or health department, building ocial or electrical inspector,
or others having statutory authority. In some circumstances,
the property owner or his/her agent assumes the role, and
at government installations, the commanding ocer or
departmental ocial may be the AHJ.

NOTE: HTP, Inc. reserves the right to modify product technical
specications and components without prior notice.

For the Installer

This storage tank must be installed by qualied and licensed
personnel. The installer should be guided by the instructions
furnished with the storage tank, and by local codes and utility
company requirements.

Installations Must Comply With:

Local, state, provincial, and national codes, laws, regulations,
and ordinances.

Table of Contents

Part 1 - General Safety Information 2
A. When Servicing the Water Heating System 3
B. System Water 3
C. Freeze Protection 3
D. Water Temperature Adjustment 3
Part 2 - Prepare the Storage Tank 3
A. Locating the Storage Tank 3
B. Water Chemistry Requirements 4
C. Optional Equipment 4
Part 3 - Piping 5
A. Plumbing 5
B. Tankless Coil Connections 5
C. Hot Water Outlet 5
D. Temperature and Pressure Relief Valve 5
E. Potable Expansion Tank 6
F. Scalding 6
G. Application 7
Part 4 - Control and Wiring 7
A. Control 7
B. Wiring 7
C. Wiring Diagram 7
Part 5 - Start-Up and Operation 7
Part 6 - Maintenance and Troubleshooting 8
Five Year Limited Warranty 10
Customer Installation Record Form 12

Part 1 - General Safety Information

This storage tank is approved for indoor installations only
and is not intended for use in swimming pool applications.
Clearance to combustible materials: 0” top, bottom, sides,
and back. Tank must have room for service: 24” front and
6” sides are minimum recommended service clearances.
(A combustible door or removable panel is acceptable front
clearance.) This storage tank has been approved for closet
installation and installation on combustible ooring. Do
not install this storage tank directly on carpeting. Install the
storage tank in a location where temperature and pressure
relief valve discharge or a leak will not result in damage to the
surrounding area. If such a location is not available, install an
auxiliary catch pan.

Installer - Read all instructions in this manual before
installing. Perform steps in the given order.

User - This manual is for use only by a qualied heating
installer / service technician. Have this storage tank serviced /
inspected annually by a qualied service technician.
NOTE: Obey all local codes. Obtain all applicable permits
before installing the storage tank.

NOTE: Install all system components and piping in such a
manner that does not reduce the performance of any re
rated assembly.
NOTE: If the storage tank is exposed to the following, do not
operate. Immediately call a qualied service technician.

1. Fire

2. Damage

3. Water
Failure to adhere to these guidelines can result in substantial
property damage, severe personal injury, or death.

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High heat sources (sources generating heat 100oF / 37oC or
greater, such as stove pipes, space heaters, etc.) may damage
plastic components of the storage tank as well as plastic
vent pipe materials. Such damages ARE NOT covered by
warranty. It is recommended to keep a minimum clearance of
8” from high heat sources. Observe heat source manufacturer
instructions, as well as local, state, provincial, and national
codes, laws, regulations and ordinances when installing this
storage tank and related components near high heat sources.

Do not use this storage tank for anything other than its
intended purpose (as described in this manual). Doing so
could result in property damage and WILL VOID product
warranty.

UNCRATING THE STORAGE TANK - Any claims for damage
or shortage in shipment must be led immediately against
the transportation company by the consignee.

A. When Servicing the Water Heating System

To avoid electric shock, disconnect electrical supply before
performing maintenance.

To avoid severe burns, allow storage tank and associated
equipment to cool before servicing.

B. System Water

Do not use petroleum-based cleaning or sealing compounds
in a water heating system. Gaskets and seals in the system
may be damaged. This can result in substantial property
damage.

Do not use “homemade cures” or “patent medicines”.
Damage to the storage tank, substantial property damage,
and/or serious personal injury may result.

C. Freeze Protection

NOTE: Consider piping and installation when determining
tank location. Place the storage tank as close to the boiler as
possible in a location not prone to freezing.

Failure of the storage tank due to freeze related damage IS
NOT covered by product warranty.

D. Water Temperature Adjustment

If the storage tank is going to have a set temperature above
120oF, you must use an ASSE 1017 rated mixing valve to avoid
severe burns or death from scalding temperatures.

COLD WEATHER HANDLING - If the storage tank has been
stored in a very cold location (BELOW 0oF) before installation,
handle with care until the components come to room
temperature. Failure to do so could result in damage to the
storage tank.

A. Locating the Storage Tank

This storage tank is certied for indoor use only. DO NOT
INSTALL OUTDOORS. Outdoor installations ARE NOT covered
by warranty.

Choose a location for the storage tank as centralized to the
piping system as possible. Also, locate the storage tank and
domestic water piping where it will not be exposed to freezing
temperatures. All piping should be insulated. Additionally, place
the storage tank so that the drain, controls, and inlets/outlets
are easily accessible.

Locate the storage tank where any leakage from the relief valve,
related piping, tank, or connections will not result in damage to
surrounding areas or lower oors of the building. The storage
tank should be located near a oor drain or installed in a drain
pan. Leakage damages ARE NOT covered by warranty.

NOTE: To save on heating costs and improve energy eciency
keep the distance between the boiler and storage tank to a
minimum to reduce heat loss from excess piping and keep
friction loss at a minimum. Ensure all piping between the boiler
and storage tank is properly insulated to minimize heat loss.

The storage tank may be located some distance from the boiler
provided the circulator meets ow requirements. The greater
the distance from the boiler to the storage tank the longer the
response will be to a call for hot water.

This storage tank must be installed vertical on a level surface.

NOTE: In the State of California, the water heater must be
braced, anchored, or strapped to avoid moving during an
earthquake. Contact local utilities for code requirements in your
area. Visit http://www.dsa.dgs.ca.gov or call 1-916-445-8100
and request instructions.

However, applicable local codes shall govern installation.
For residential water heaters of a capacity of greater than 52
gallons, consult the local building jurisdiction for acceptable
bracing procedures.

NOTE: If you do not provide the minimum clearances shown
in Figure 1, it might not be possible to service the storage tank
without removing it from the space.

Households with small children, disabled, or elderly persons
may require a 120oF or lower temperature setting to prevent
severe personal injury or death due to scalding.

Part 2 - Prepare the Storage Tank

Remove all sides of the shipping crate to allow the tank to be
moved into its installation location.

This storage tank must not be located near ammable liquids
such as gasoline, butane, liqueed propane, adhesives, solvents,
paint thinners, etc., as the controls of this storage tank could
ignite these vapors and cause an explosion resulting in property
damage, severe personal injury, or death.

Ensure the location can support the entire lled weight of the
storage tank. Failure to properly support the storage tank could
result in property damage, severe personal injury, or death.

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RECOMMENDED SERVICE CLEARANCE

Figure 1 - Recommended Service Clearances

B. Water Chemistry Requirements

Chemical imbalance of the water supply may aect eciency
and cause severe damage to the storage tank and associated
equipment. HTP recommends having water quality
professionally analyzed to determine whether it is necessary to
install a water softener. It is important that the water chemistry
be checked before installing the storage tank, as water quality
will aect the reliability of the system. In addition, operating
temperatures above 135oF will further accelerate the build-up of
lime scale and may shorten the service life of the storage tank.
Failure of a storage tank due to lime scale build-up, low pH, or

other chemical imbalance IS NOT covered by the warranty.
Outlined below are water quality parameters that need to be
met in order for the system to operate eciently for many
years.

Water Hardness

Water hardness is mainly due to the presence of calcium and
magnesium salts dissolved in water. The concentration of these
salts is expressed in mg/L, ppm, or grains per gallon as a measure
of relative water hardness. Grains per gallon is the common
reference used in the US water heater industry. Hardness
expressed as mg/L or ppm may be divided by 17.1 to convert to
grains per gallon. Water may be classied as very soft, slightly
hard, moderately hard, or hard based on its hardness number.
The minerals in the water precipitate out as the water is heated
and cause accelerated lime scale accumulation on a heat transfer
surface. This lime scale build-up may result in premature failure
of the storage tank. Operating temperatures above 135oF will
further accelerate the build-up of lime scale and may shorten
the service life of the storage tank.
Water that is classied as hard and very hard must be softened
to avoid storage tank failure.

CLASSIFICATION MG/L OR PPM GRAINS/GAL

Soft 0 - 17.1 0 - 1

Slightly Hard 17.1 - 60 1 - 3.5

Moderately Hard 60 - 120 3.5 - 7

Hard 120 - 180 7 - 10.5

Very Hard 180 and over 10.5 and over

If the hardness of the water exceeds the maximum level of 7
grains per gallon, the water should be softened to a hardness
level no lower than 5 grains per gallon. Water softened as low
as 0 to 1 grain per gallon may be under-saturated with respect
to calcium carbonate, resulting in water that is aggressive and
corrosive.

pH of Water

pH is a measure of relative acidity, neutrality, or alkalinity.
Dissolved minerals and gases aect water pH. The pH scale
ranges from 0 to 14. Water with a pH of 7 is considered neutral.
Water with pH lower than 7 is considered acidic. water with a
pH higher than 7 is considered alkaline. A neutral pH (around

7) is desirable for most potable water applications. Corrosion

damage and tank failures resulting from water pH levels
of lower than 6 or higher than 8 ARE NOT covered by
warranty. The ideal pH range for water used in a storage tank

is 7.2 to 7.8.

Total Dissolved Solids

Total Dissolved Solids (TDS) is a measurement of all minerals
and solids dissolved in a water sample. The concentration of
TDS is usually expressed in parts per million (ppm).
Water with a high TDS concentration will greatly accelerate
lime and scale formation in the hot water system. Most high
TDS concentrations precipitate out of the water when heated.
This can generate a scale accumulation that will greatly reduce
the service life of the storage tank.

The manufacturer of the storage tank has no control over
water quality, especially TDS levels in your system. TDS in
excess of 2000 ppm will accelerate lime and scale formation
on the element or the heat exchanger. Storage tank failure
due to TDS in excess of 2000 ppm IS NOT covered by warranty.

Failure of a storage tank due to lime scale build-up IS NOT
covered by warranty.

Hardness: 7 grains
Chloride levels: 100 ppm
pH levels: 6 - 8
TDS: 2000 ppm
Sodium: 20 mG/L

C. Optional Equipment

Below is a list of optional equipment available from HTP:

• Aquastat Cover with BX and Line Cord (GL-50 Models
Only) Part # GL-KT1

• Aquastat Cover with BX, Line Cord, and Bronze Pump
(GL-50 Models Only) Part # GL-KT2

Part 3 - Piping

A. Plumbing

It is mandatory that all plumbing be done in accordance
with federal, local, and state plumbing codes and practices.

lp-181 Rev. 3.3.15