HTP SSP 30, SSP 80, SSP 100, SSP 40, SSP 50 Installation, Start-up And Maintenance Instructions
...Page 1
Installation
Start-Up
Maintenance
Parts
S
uperstor Pro
Indirect Fired
Water Heaters
Warranty
For Residential and Commercial Use
SSP Models
This manual must only be used by a qualied 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.
California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth
defects, or other reproductive harm.
HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors
in literature.
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.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
272 Duchaine Blvd. New Bedford, MA 02745 www.htproducts.com
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 2
2
The following dened 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 water heater. 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 ocial 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
ocer or departmental ocial may be the AHJ.
NOTE: HTP reserves the right to modify product technical specications
and components without prior notice.
For the Installer
This water heater must be installed by qualied and licensed personnel.
The installer should be guided by the instructions furnished with the
water heater, 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. Heater Water 3
C. Freeze Protection 3
D. Water Temperature Adjustment 3
Part 2 - Prepare the Water Heater 3
A. Locating the Water Heater 3
B. Water Chemistry Requirements 4
Part 3 - Piping 6
A. Plumbing 6
B. Boiler Connections 6
C. Domestic Piping Inlet 6
D. Auxiliary Connections 6
E. Temperature and Pressure Relief Valve 6
F. Scalding 7
G. Potable Expansion Tank 7
H. Pressure Drop Sizing For Circulator 7
I. Applications 8
Part 4 - Heater Control and Wiring 9
A. Control 9
B. Wiring 9
C. Wiring Diagrams 9
Part 5 - Start-Up and Operation 10
Part 6 - Maintenance and Troubleshooting 11
Limited Warranty 13
Customer Installation Record Form 15
Part 1 - General Safety Information
This water heater is approved for indoor installations only and is
not intended for use as a pool heater. Clearance to combustible
materials: 0” top, bottom, sides, and back. Heater must have room
for service: 24” front, 6” top, and 0” sides are minimum recommended
service clearances. (A combustible door or removable panel is
acceptable front clearance.) This water heater has been approved
for closet installation and installation on combustible ooring. Do
not install directly on carpeting. Install the water heater 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 qualied heating installer
/ service technician. Have this water heater serviced / inspected
annually by a qualied service technician.
FAILURE TO ADHERE TO THESE GUIDELINES CAN RESULT
IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL
INJURY, OR DEATH.
NOTE: Obey all local codes. Obtain all applicable permits before
installing the water heater.
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 water heater is exposed to the following, do not
operate. Immediately call a qualied service technician.
1. Fire
2. Damage
3. Water
Failure to follow this information could result in property damage,
severe personal injury, or death.
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 3
3
High heat sources (sources generating heat 100oF / 37oC or
greater, such as stove pipes, space heaters, etc.) may damage
plastic components of the water heater 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 water heater and related
components near high heat sources.
DO NOT use this indirect water heater in steam applications.
Doing so will result in damage to the water heater. Such damages
ARE NOT covered by warranty.
Do not use this water heater 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 WATER HEATER - 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 water heater and associated equipment
to cool before servicing.
B. Heater 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
water heater, substantial property damage, and/or serious personal
injury may result.
NOTICE FOR SINGLE-WALL HEAT EXCHANGER MODELS
Per the Uniform Plumbing Code:
Single-wall heat exchangers are permitted if they satisfy all of the
following requirements:
The heat exchanger medium is potable water or contains only
substances which are recognized as safe by the US Food and Drug
Administration (FDA).
The pressure of the heat exchanger medium is maintained less
than the normal minimum operating pressure of the potable water
system.
The equipment is permanently labeled to indicate that only
additives recognized as safe by the FDA shall be used as the heat
transfer medium.
Other heat exchanger designs may be permitted where approved
by the AHJ.
In water heaters with single wall heat exchangers, the heat transfer
uid must be water or nontoxic food grade glycol, FDA rated
“generally recognized as safe” (GRAS) and having a toxicity rating or
class of 1, as listed in Clinical Toxicology of Commercial Products, 5th
edition. Ensure the system is permanently labeled to indicate any
additives used in the heat transfer uid.
NEVER use any toxic chemical, including automotive, standard glycol
antifreeze, or ethylene glycol made for hydronic (non-potable)
systems. These chemicals can attack gaskets and seals in water
systems, are poisonous if consumed, and can cause personal injury
or death.
D. Water Temperature Adjustment
If the water heater 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.
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.
Approximate Time / Temperature Relationships in Scalds
120oF More than 5 minutes
125oF 1 1/2 to 2 minutes
130oF About 30 seconds
135oF About 10 seconds
140oF Less than 5 seconds
145oF Less than 3 seconds
150oF About 1 1/2 seconds
155oF About 1 second
Table 1 - Approximate Time / Temperature Relationships in Scalds
Part 2 - Prepare the Water Heater
Remove all sides of the shipping crate to allow the heater to be moved
into its installation location.
COLD WEATHER HANDLING - If the water heater 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 water heater.
NOTE: A drain valve is included with the water heater.
A. Locating the Water Heater
C. Freeze Protection
NOTE: Consider piping and installation when determining heater
location. Place the water heater as close to the boiler as possible in a
location not prone to freezing.
Failure of the water heater due to freeze related damage IS NOT
covered by product warranty.
High heat sources (generating heat 100oF / 37oC or greater, such
as boiler ue pipes, space heaters, etc.) may damage plastic
components of the water heater 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 water heater and related components near high
heat sources.
This water heater is certied for indoor use only. DO NOT INSTALL
OUTDOORS. Outdoor installations ARE NOT covered by warranty.
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 4
4
Choose a location for the water heater as centralized to the piping
system as possible. Also, locate the water heater and domestic water
piping where it will not be exposed to freezing temperatures. All
piping should be insulated. Additionally, place the water heater so that
the drain, controls, and inlets/outlets are easily accessible.
Locate the water heater 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 water heater
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 eciency keep
the distance between the boiler and water heater to a minimum
to reduce heat loss from excess piping and keep friction loss at a
minimum. Ensure all piping between the boiler and water heater is
properly insulated to minimize heat loss.
The water heater may be located some distance from the boiler
provided the circulator meets ow requirements through the coil. The
greater the distance from the water heater to the boiler the longer the
response will be to a call for hot water.
This water heater 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 water heater without
removing it from the space.
NOTE: A combustible door or removable panel is acceptable front
clearance.
Ensure the location can support the entire lled weight of the water
heater. Failure to properly support the water heater could result in
property damage, severe personal injury, or death.
This water heater must be installed upright in the vertical position as
described in this manual. DO NOT attempt to install this water heater
in any other orientation. Doing so will result in improper water
heater operation and property damage, and could result in serious
personal injury or death.
This water heater must not be located near ammable liquids such
as gasoline, butane, liqueed propane, adhesives, solvents, paint
thinners, etc., as the controls of this water heater could ignite these
vapors and cause an explosion resulting in property damage, severe
personal injury, or death.
B. Water Chemistry Requirements
Chemical imbalance of the water supply may aect eciency and
cause severe damage to the appliance and associated equipment.
Water quality must be professionally analyzed to determine whether
it is necessary to treat the water. Various solutions are available to
adjust water quality. Adverse water quality will aect the reliability
of the system. In addition, operating temperatures above 135oF will
accelerate the build-up of lime scale and possibly shorten appliance
service life. Failure of an appliance due to lime scale build-up, low
pH, or other chemical imbalance IS NOT covered by the warranty.
RECOMMENDED SERVICE CLEARANCES
ZERO
MAXIMUM 2"
Figure 1 - Recommended Service Clearances
ZERO CLEARANCE
24" MIN.
CATCH PAN DIMENSIONS
DIA. OF WATER HEATER
PLUS 2" MINIMUM
ZERO
TO OPEN DRAIN
LINE SHOULD BE AT
LEAST 3/4" ID AND
PITCHED FOR PROPER
DRAINAGE.
LP-451-G
03/29/17
The water must be potable, free of corrosive chemicals, sand,
dirt, and other contaminates. It is up to the installer to ensure the
water does not contain corrosive chemicals or elements that can
damage the heat exchanger. Potable water is dened as drinkable
water supplied from utility or well water in compliance with EPA
secondary maximum contaminant levels (40 CFR Part 143.3). If
the water contains contaminants higher than outlined by the EPA,
water treatment is recommended and additional, more frequent
maintenance may be required.
If you suspect that your water is contaminated in any way,
discontinue use of the appliance and contact an authorized
technician or licensed professional.
• Water pH between 6.5 and 8.5
• pH levels below 6.5 can cause an increase in the rate of
corrosion. pH of 8.5 or higher can potentially cause lime
scale build-up
• Maintain water pH between 6.5 and 8.5. Check with litmus
paper or have it chemically analyzed by a local water
treatment company.
• If the pH is not between 6.5 and 8.5, consult a local water
treatment company for solutions.
• Hardness less than 12 grains (200 mg/L) (Residential Use
- water temperatures below 140oF)
• Hardness less than 7 grains (120 mg/L) (Commercial Use
- water temperatures of 140oF and greater)
• Hardness levels above the required amounts can lead to
lime scale build-up throughout the system. Water below 5
grains/gallon (85 mg/L) may be over softened.
• Consult local water treatment companies for unusually
hard water areas (above the required amounts) or for
other treatment solutions if water is being over softened
(below 5 grains/gallon [85 mg/L]).
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 5
5
A
C
D
B
30 MODEL
TOP
VIEW
F
OUTLET
BOILER IN
BOILER OUT
DRAIN VALVE
G
H
RELIEF
VALVE
THERMOSTAT
CONNECTION
AUX/RECIRC
INLET
THERMOSTAT
ACCESS COVER
BOILER IN
BOILER OUT
E
A
D
B
C
40 / 50 / 60 / 80 / 100 MODELS
INDIRECT WATER HEATER
MODEL A B C D E F G H
30
42-1/8"
40
50
60
80
100
MODEL
30
40
50
60
80
100
*DOE TEST METHOD BASED ON 77 F TEMPERATURE RISE, 58 / 135 W/BOILER WATER AT 180 F
NOTE: TANK RECOVERY FROM COLD START WILL BE BETWEEN 10-13 MINUTES WHEN SIZED WITH CORRECT FLOW RATE, BOILER SIZE AND
PRESSURE DROP RATINGS FROM LIST IN ABOVE CHART.
CONTINUOUS FLOW RATING CALCULATION:
FIRST HOUR RATING - (.75 * GALLON CAPACITY) = CONTINUOUS FLOW RATING
HEAT
EXCHANGER
SURFACE
15 SQ. FT.
18 SQ. FT.
Figure 2 - Specications and Dimensions
• Chloride concentration less than 100 ppm (mg/L)
• Do not ll appliance or operate with water containing
chlorides in excess of 100 ppm (mg/L).
• Using chlorinated fresh water should be acceptable as levels
are typically less than 5 ppm (mg/L).
• Do not connect the appliance to directly heat swimming
pool or spa water.
• Total Dissolved Solids (TDS) less than 500 ppm (mg/L)
• Total dissolved solids are minerals, salts, metals, and charged
particles that are dissolved in water.
52-5/8"
PRESSURE
19-3/8"
5-7/8" 21"
23-1/2"
TEST
WORKING
PRESSURE
300 PSI 150 PSI
CAPACITY
U.S. GAL.
28 GAL
1-3/8" 4" 8" 4"
180 BOILER
WATER FIRST
HOUR RATINGS
(GAL) *
140 F
228 130,000 8 GPM 1.7 FT 95 LBS
266 155,000 10 GPM 2.3 FT 111 LBS
287 155,000 10 GPM 2.3 FT 127 LBS
303 155,000 10 GPM 2.3 FT 140 LBS
347 175,000 12 GPM 2.3 FT 157.5 LBS
393 195,000 14 GPM 2.3 FT 195 LBS
180 F
BOILER
BTU/SIZE
RECOMMENDED
FLOW RATE
58 GAL
PRESSURE DROP
RECCOMENDED
LAG 83"4/1-45
LAG 84"8/5-66
LAG 87"96
FLOW
DOMESTIC
CONNECTION
3/4" NPTM
1" NPTM
AT
• The greater the amounts of TDS present, the higher the
corrosion potential due to increased conductivity in the
water.
• If using softened water to ll the appliance, it is still possible
to have high TDS. This water can be corrosive. Consult local
water treatment companies for other treatment solutions to
reduce this aect.
*NOTE: To promote appliance service life, it is strongly recommended
to follow the maintenance procedures in this manual.
MTPN 2/1-1LAG 89"4/1-02"8/1-8"2/1-72"8/7-06
DRY
WEIGHT
LP-451-E
03/29/17
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 6
6
Part 3 - Piping
A. Plumbing
It is mandatory that all plumbing be done in accordance with federal,
local, and state plumbing codes and practices. Failure to properly
install the water heater WILL VOID the warranty. It is also necessary
to use both thread tape and pipe dope on all mechanical plumbing
connections.
Never connect auxiliary connections to any system that uses glycol
or other solutions formulated for hydronic systems. These auxiliary
connections are to be used only in a potable water system. Failure
to follow this warning could result in severe personal injury or
death.
When lling the water heater, open a hot water tap to release air in
the tank and piping. Failure to do so could lead to improper water
heater operation and damage to components.
DO NOT pipe this water heater with black iron, galvanized steel,
steel, or lead pipe. Doing so will result in premature product failure
and property damage, and WILL VOID the product warranty.
B. Boiler Connections
Use two wrenches when tightening water piping at the heater. Use
one wrench to prevent the heater return or supply line from turning.
Failure to prevent piping connections from turning could cause
damage to water heater components.
DO NOT use this indirect water heater in steam applications. Doing
so will result in damage to the water heater. Such damages ARE NOT
covered by warranty.
Use a 1” nominal minimum pipe size when piping with zone valves or
circulators.
On the water heater, the boiler supply connects to the outlet of the
circulator. The circulator inlet is to be connected to the hot outlet
side of the boiler. Be sure that the arrow on the circulator is facing
the correct ow direction. (See pressure drop sizing for circulator, this
manual.) On the tank, the boiler return connects to the return side of
the boiler. The return(s) from heating loop(s) should have a ow check
or swing check valve installed before the return pipe from the tank.
C. Domestic Piping Inlet
Never use dielectric ttings or galvanized steel ttings on any
domestic water connections. Use only copper or brass ttings.
Failure to do so will result in premature water heater failure. Such
failure IS NOT covered by warranty.
Use both thread tape and pipe dope to connect to the all stainless
steel 3/4” domestic inlet and outlet. A shut-o valve between the city
water supply and tank inlet is recommended for ease of service.
It may be recommended to use a back ow preventer - check local
codes. If a back ow preventer or no return valve is used, a thermal
expansion tank must be installed on the cold water supply between
the tank and valve. If the tank is replacing a tankless coil in the boiler,
disconnect coil plumbing and use the cold water inlet and hot water
outlet pipes for the water heater.
D. Auxiliary Connections
The auxiliary connections are additional connections for a recirculation
line. These connections must be installed in accordance with all local
and national codes or any applicable standard that prevails. Auxiliary
connections are 3/4” on all models. Never use dielectric unions or
galvanized steel ttings. Use only copper or brass ttings. Sealant must
be used on all connections.
E. Temperature and Pressure Relief Valve
On all models, an appropriate temperature and pressure (T&P) valve
must be supplied and installed as detailed in the piping diagrams in
this installation manual.
Use both thread tape and pipe dope to install an NPT brass T&P
relief valve for hot water heaters, as required by local codes but
not less than valves certied as meeting the requirements for relief
valves for hot water heaters (ANSI Z21.22 / CSA 4.4) by a nationally
recognized lab that maintains periodic inspection of production
listed equipment. Make sure the relief valve is sized to the BTU/Hour
capacity of the water heater. The T&P valve must be plumbed down
so discharge can exit at least 6” above the structural oor. The relief
line cannot be in contact with any live electrical parts. If the relief
valve constantly weeps install an expansion tank. See expansion
tank manufacturer’s instructions for suggestions.
To avoid water damage or scalding due to relief valve operation:
• Discharge line must be connected to relief valve outlet and
run to a safe place of disposal. Terminate the discharge line
in a manner that will prevent possibility of severe burns or
property damage should the relief valve discharge.
• Discharge line must be as short as possible and the same
size as the valve discharge connection throughout its
entire length.
• Discharge line must pitch downward from the valve
and terminate at least 6” above the oor drain, making
discharge clearly visible.
• The discharge line shall terminate plain, not threaded, with
a material serviceable for temperatures of 375oF or greater.
• Do not pipe discharge to any location where freezing could
occur.
• No valve may be installed between the relief valve and
heater or in the discharge line. Do not plug or place any
obstruction in the discharge line.
• Test the operation of the relief valve after lling and
pressurizing the system by lifting the lever. Make sure the
valve discharges freely. If the valve fails to operate correctly,
immediately replace with a new properly rated relief valve.
• Test T&P valve at least once annually to ensure the waterway
is clear. If valve does not operate, turn the heater “o” and
call a plumber immediately.
• Take care whenever operating relief valve to avoid scalding
injury or property damage.
FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD
RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING
IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE
PERSONAL INJURY, OR DEATH.
Do not thread a cap or plug into the relief valve or relief valve
line under any circumstances! Explosion and property damage,
serious injury, or death may result.
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 7
RE-INSPECTION OF T&P RELIEF VALVES: T&P valves should be
inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if
necessary, by a licensed plumbing contractor or qualied service
technician to ensure that the product has not been aected by
corrosive water conditions and to ensure that the valve and
discharge line have not been altered or tampered with illegally.
Certain naturally occuring conditions may corrode the valve and
its components over time, rendering the valve inoperative. Such
conditions can only be detected if the valve and its components
are physically removed and inspected. Do not attempt to
conduct an inspection on your own. Contact your plumbing
contractor for a re-inspection to assure continued safety.
FAILURE TO RE-INSPECT THE T&P VALVE AS DIRECTED COULD
RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE BUILDUP WHICH CAN RESULT IN PROPERTY DAMAGE, SERIOUS
PERSONAL INJURY, OR DEATH.
F. Scalding
An ASSE 1017 or ASSE 1070 temperature limiting or mixing valve
is recommended in installations servicing disabled or elderly
persons, or children. Mixing valves do not eliminate the risk of
scalding.
To avoid scalding:
• Set the water heater set point temperature as low as
possible.
• Feel water before bathing or showering.
• If thermostatic valves are required, use devices specically
designed for such purpose. Install these devices in
accordance with instructions provided by the manufacturer.
Failure to install a temperature limiting or mixing valve and
follow these instructions could result in property damage, severe
personal injury, or death due to scalds.
7
This water heater can
deliver scalding water. Be
careful whenever using
hot water to avoid scalding
injury. Certain appliances
such as dishwashers and
automatic clothes washers
may require increased
water temperatures. By
setting the thermostat
on this heater to obtain
the increased water
temperature required by
these appliances you may
create the potential for
scald injury.
To protect against injury,
install a mixing valve in the
water system. This valve
will reduce point of use
discharge temperatures by
mixing cold and hot water
in branch supply lines.
Such valves are available from your local plumbing supplier.
Table 1 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.
G. Potable Expansion Tank
A potable hot water expansion tank may be required to oset heated
water expansion. If there is a back ow preventer or any other type
of no return or check valve in the system a thermal expansion tank IS
MANDATORY. The expansion tank must be sized for the entire water
volume of the hot water system. A weeping relief valve indicates the
need for an expansion tank. See the Typical Expansion Tank example in
the Piping section for details.
H. Pressure Drop Sizing For Circulator
The boiler circulator ow rate must meet the requirements found in
the water heater specications, Part 2, this manual, or the published
ratings cannot be achieved. The ow chart below represents the pipe
run, water heater, and heat exchanger ONLY and does not include
any ow checks, zone valves, or friction loss through the boiler. That
resistance must be added to the value found in the following chart.
Figure 3 - Pressure Drop through the Heat Exchanger
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 8
8
I. Applications
ZONE RETURN
COLD
WATER
SUPPLY
ZONE
VALVE
HOT WATER
OUTLET
IT IS RECOMMENDED THAT 1" LINES AND 1" ZONE VALVES
ARE USED FOR INDIRECT WATER HEATER ZONE
BOILER
CIRCULATOR
LP-451-B
03/29/17
TEMPERATURE/PRESSURE
LP-451-C
03/29/17
MIXING
VALVE
RELIEF VALVE
Figure 4 - Zoning with Zone Valves Figure 5 - Zoning with Circulators
TUB
SHOWER
SINK
CIRCULATOR PUMP
w/INTERNAL CHECK
SWING CHECK VALVE
BOILER
PIPING NOTES:
The following notes are applicable to all of
the piping applications demonstrated on this
page.
1. Minimum pipe size should match
connection size. Upsize pipe accordingly if
greater ow is required.
2. A thermal expansion tank suitable for
potable water must be sized and installed
within this piping system between the
backow preventer and the cold water inlet.
3. All circulators should have an integral ow
check.
4. Drains and check valve between unit and
water heater will assist in purging air from
system.
5. This drawing is meant to demonstrate
system piping only. The installer is responsible
for all equipment and detailing required by
local codes. In Massachusetts, you must install
a vacuum relief valve per 248 CMR.
6. Mixing valve application is optional, but
recommended to help prevent scalding. See
Part 3 for more information.
MIXING VALVE
SHUT-OFF
VALVE
CIRCULATOR
PUMP
w/CHECK
VALVE
AUXILIARY LINE
T&P LINE
CHECK
VALVE
EXPANSION
TANK
COLD INLET
lp-451 Rev. 001 Rel. 001 Date 7.25.17
LP-451-A
03/29/17
Figure 6 - Typical Expansion Tank Application with Auxiliary Line
Page 9
Part 4 - Heater Control and Wiring
A. Control
A surface mount thermostatic control has been provided for accurate
temperature adjustment.
B. Wiring
Wiring is to be done in accordance with all applicable local and state
codes. Turn o all power related to the boiler before starting any
wiring procedures. It is recommended that a disconnect switch be
installed between the boiler control and the water heater.
When wiring the water heater and controls be sure to label all wires
to ease future maintenance. Wiring errors can cause improper and
dangerous operation.
A thermostat connection has been provided on the top of the water
heater for easy wiring and accurate control. See Figure 7. Connect the
wires from the thermostat to the terminals marked + (Positive) or (Negative).
NEGATIVE
POSITIVE
LP-451-H
03/29/17
9
C. Wiring Diagrams
Figure 8 - Wiring with Circulators
Figure 7 - Thermostat Connection
Figure 9 - Wiring with Zone Valves
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 10
10
Part 5 - Start-Up and Operation
1. Fill the water heater by opening the cold water shut-o valve. Make
certain the eld installed drain valve is completely closed. Purge air
from the system by opening a hot water outlet at a xture in a kitchen
or bathroom. When water ows freely from the outlet, the system is
purged.
When lling the water heater, open a hot water tap to release air in
the tank and piping to ensure proper water heater operation. Failure
to ensure the water heater is full before turning on the system will
result in damage to the water heater, and could result in property
damage. Such damages ARE NOT covered by warranty.
2. Check the system for leaks.
Fix any leaks before continuing the installation. Failure to do so could
result in property damage or personal injury.
3. After ensuring there are no leaks within the system, ush the
system to clear any soldering residue. Many soldering uxes contain
Zinc Chloride, which can
corrode stainless steel.
Draw at least three times
the volume of the water
heater to properly ush the
system.
4. Initiate a call for hot
water. Ensure each zone
valve or circulator operates
only when its thermostat
calls for heat. Purge each
zone of air to ensure proper
operation.
5. Set the water heater to
the desired temperature.
Boiler high limit should
be set at least 20oF
higher than the heater
temperature. Set the low
limit of the boiler control at
the minimum setting - this
will call the burner on only
to satisfy the tank control.
A water heater temperature setting of 120oF is recommended.
However, a lower temperature setting may be required to comply with
local and state codes for normal operation. The dierential should
be set at 10 to 15oF. Installation conditions may require a higher or
lower temperature setting. A mixing valve in conjunction with a high
temperature setting may be used for high demand applications (spas,
hot tubs, whirlpools).
6. When the system is completely ushed, purged of air, and the
temperature is set, turn on the boiler. Observe operation. Ensure the
boiler shuts down after the indirect water heater set point is satised.
Risk of scald injury increases as you increase water temperature.
3
9
Figure 10 - Replacement Parts
2
1
4
6
Item # Part # Description
1 6070P-035 Terminal Block w/ Screws
6070P-038 Dip Tube Cold Inlet - 30 Gal
6070P-139 Dip Tube Cold Inlet - 40 Gal
2
7700P-062 Dip Tube Cold Inlet - 50 Gal
6070P-141 Dip Tube Cold Inlet - 60 Gal
6070P-142 Dip Tube Cold Inlet - 80 and 100 Gal
6070P-044 Dip Tube Auxiliary Inlet - 30 Gal
6070P-045 Dip Tube Auxiliary Inlet - 40 and 60 Gal
3
6070P-046 Dip Tube Auxiliary Inlet - 50 Gal
6070P-147 Dip Tube Auxiliary Inlet - 80 Gal
6070P-140 Dip Tube Auxiliary Inlet - 100 Gal
4 TD1012 Thermostat
5 6060P-633 Mounting Clip
6 6060P-634 Protective Cover
7 H3000 Electric Access Panel
8 6075P-006 Screws (#8 Self-Threading)
9 6070P-009 Combination Drain Valve
Table 2 - Replacement Parts List
5
LP-451-J
LP-451-J
03/29/17
03/29/17
7
8
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 11
Part 6 - Maintenance and Troubleshooting
Periodic maintenance should be performed by a qualied service
technician to ensure all equipment is operating safely and eciently.
The owner should make necessary arrangements with a qualied
Annual Maintenance Activities Date Last Completed
Piping 1st Year 2nd Year 3rd Year 4th Year
Near heater piping Check heater and system piping for any sign of leakage; make sure
pipes are properly supported.
System
Visual Do a full visual inspection of all system components. Ensure all
components (including boilers, water treatment systems, mixing
valves, circulators, etc.) are operating properly and have been
maintained.
Functional Test all functions of the system. Perform any maintenance required
by local codes. Verify system pressure is in the safe operating range.
Temperatures Check control for temperature accuracy.
*Verify safe settings on Mixing Valve (if installed in system).
Electrical
Smoke and CO
Detectors
Circuit Breakers Check to see that the circuit breaker is clearly labeled. Exercise circuit
Connections Check wire connections. Make sure they are tight.
Relief and Drain Valve
Relief Valve Lift and release the relief valve on the water heater. Make certain
Drain Valve Open the drain valve and drain a few quarts of water from the
Final Inspection
Check for
Combustibles
Checklist Verify that you have completed the entire checklist. WARNING:
Homeowner Review what you have done with the homeowner.
Initial and Date after Inspection / Service. Continue Inspections Annually beyond the
Fourth Year.
Table 3 - Maintenance Activities Checklist - *If Applicable to System
*Verify devices are installed and working properly. Change batteries
if necessary.
breaker.
that the valve operates properly by allowing several gallons to ush
through the discharge line. Replace if valve is blocked or does not
operate properly.
NOTE: TAKE CAUTION WHEN OPERATING RELIEF VALVE. DISCHARGED
WATER MAY PRESENT A SCALD RISK.
bottom of the tank to ush any hard water deposits. Replace if valve
is blocked or does not operate properly.
NOTE: TAKE CAUTION WHEN OPERATING DRAIN VALVE. DRAINED
WATER MAY PRESENT A SCALD RISK.
Check area around heater for combustible materials such as gasoline
or paint thinner. If combustible materials are found, move away from
the heater to a safe location.
FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH.
heating contractor for periodic maintenance of the heater. Installer
must also inform the owner that the lack of proper water heater care
and maintenance may result in hazardous conditions.
11
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 12
12
Troubleshooting
No Hot Water Not Enough Hot Water
Problem Possible Solution Problem Possible Solution
Zone valve not opening Open manually to replace Zone valve restriction 1” full bore replace zone valve
Circulator not operating Check or replace Circulator arrow reversed Reverse circulator
Tank control set too low Raise tank temperature* Tank temperature too low Raise tank temperature*
Boiler control set too low Raise boiler temperature Boiler temperature too low Raise boiler temperature
Wiring incorrect Check wiring Boiler sized too small Check sizing chart
Tank control failure Replace control Tank sized too small Check sizing chart
Zone valve failure Replace valve Demand ow rate too high
Circulator failure Replace circulator Air trap in loop
Heat and tank come on together
Air trap in loop Purge air
Not enough space heat
Slow recovery Circulator head capacity too low
T&P Valve Discharges Hot Tubs, Spas, Multiple Showers, High Demand
Problem Possible Solution Problem Possible Solution
Tank temperature too high Lower tank temperature Pressure too low Check line pressure for restriction
Water expands when heated Install expansion tank Tank recovery slow Slow startup boiler. See chart
Water pressure too high
Table 4 - Troubleshooting - *See scald warning below.
Install pressure reducing
valve
Not enough hot water
Install mixing valve. Raise tank
temperature
Purge air
Install ow regulator
Check wiring or set indirect as
priority over heating
Draw tank down and lower ther-
mostat. Recheck.
Boiler sized too small.
Consult chart.
Boiler sized too small. See chart
Check ow rate. Compare to
chart
Demand too great. Check ow
rates and compare to chart.
Install mixing valve and/or ow
restricting valve and raise tank
and boiler temperature.*
The risk of scald injury increases as you increase water temperature.
Use a water tempering or mixing valve and extreme caution when
using hot water to avoid scald injury. Consult codes for conformance.
Failure to follow the instructions in this warning statement could
result in serious personal injury or death from scalds.
lp-451 Rev. 001 Rel. 001 Date 7.25.17
If draining of the water heater is necessary, open the T&P valve or
a hot water tap to prevent vacuum buildup in the tank and piping.
Page 13
13
SuperStor Pro
Indirect Fired Water Heater / Solar Water Heater
Limited Warranty
For Residential and Commercial Use
HTP warrants each indirect red water heater to be free from defects
in materials and workmanship according to the following terms,
conditions, and time periods. UNLESS OTHERWISE NOTED THESE
WARRANTIES COMMENCE ON THE DATE OF INSTALLATION. This
limited warranty is only available to the original consumer
purchaser (hereinafter “Owner”) of the water heater, and is non-
transferable.
Standard Residential Use Warranty
(Ten [10] years – Tank, One [1] year – Components)
Standard Residential Use shall mean water heaters not registered
online with HTP used in a single family dwelling, or usage in a
multiple family dwelling, provided that the water heater services
only one (1) dwelling in which the Owner resides on a permanent
basis and operating temperatures do not exceed 140oF.
Extended Residential Use Warranty
(Lifetime – Tank, One [1] year – Components)
Extended Residential Use coverage shall apply to residential use
water heaters registered online with HTP at www.htproducts.com/
sspwarranty within 90 days of the installation date. This Extended
Residential Use Warranty is available at an additional charge. See
the information provided on the following page of this document
for registration details.
Standard Commercial Use Warranty
(Five [5] years – Tank, One [1] year – Components)
Standard Commercial Use shall mean any usage not falling within
the denition of a “standard residential use” setting.
COVERAGE
A. During the rst year after the original date of installation in the
dwelling, HTP warrants that it will repair or replace, at its option,
any defective or malfunctioning component of the water heater.
Replacement components will be warranted for ninety (90) days.
B. Should a defect or malfunction result in a leakage of water from
the water heater within the above-stated warranty periods due to
defective material or workmanship, malfunction, or failure to comply
with the above warranty, with such defect or malfunction having
been veried by an authorized HTP representative, HTP will replace
the defective or malfunctioning water heater with a replacement of
the nearest comparable model available at the time of replacement.
The replacement water heater will be warranted for the unexpired
portion of the applicable warranty period of the original water heater.
C. In the event of a leakage of water of a replacement water heater
due to defective material or workmanship, malfunction, or failure to
comply with the above warranty, HTP reserves the right to refund
to the Owner the published wholesale price available at the date of
manufacture of the original water heater.
D. If government regulations, industry certication, or similar
standards require the replacement water heater or component(s)
to have features not found in the defective water heater or
component(s), the Owner will be charged the dierence in price
represented by those required features. If the Owner pays the price
dierence for those required features and/or to upgrade the size
and/or other features available on a new replacement water heater
or component(s), the Owner will also receive a complete new limited
warranty for that replacement water heater or component(s).
E. If at the time of a request for service the Owner cannot provide
a copy of the original sales receipt or the warranty registration, the
warranty period for the water heater shall then be deemed to have
commenced thirty (30) days from the date of manufacture of the
water heater and NOT the date of installation of the water heater.
F. This warranty extends only to water heaters utilized in heating
applications that have been properly installed by qualied
professionals based upon the manufacturer’s installation instructions.
G. It is expressly agreed between HTP and the Owner that repair,
replacement, or refund are the exclusive remedies of the Owner.
OWNER RESPONSIBILITIES
The Owner or Installer must:
1. Have a relief valve bearing the listing marks of the American
Society of Mechanical Engineers (ASME) installed with the water
heater assembly in accordance with federal, state, and local codes.
2. Have a vacuum relief valve certied to ANSI Z21.22 - Relief Valves for
Hot Water Supply Systems installed with the water heater assembly
in accordance with federal, state, and local codes and in installations
prone to vacuum related damages.
3. Maintain the water heater in accordance with the maintenance
procedure listed in the manufacturer’s provided instructions.
4. Maintain all related system components in good operating
condition.
5. Use the water heater in an open system, or in a closed system with
a properly sized and installed thermal expansion tank.
6. Use the water heater at water pressures not exceeding the working
pressure shown on the rating label.
7. Keep the water heater free of damaging scale deposits.
8. Make provisions so if the water heater or any component or
connection thereto should leak, the resulting ow of water will not
cause damage to the area in which it is installed.
WARRANTY EXCLUSIONS
This limited warranty will not cover:
1. Any water heater purchased from an unauthorized dealer or online
retailer.
2. Any water heater not installed by a qualied heating installer/
service technician, or installations that do not conform to ANSI,
CSA, and/or UL standards, as well as any applicable national or local
building codes.
3. Service trips to teach you how to install, use, maintain, or to bring
the water heater installation into compliance with local building
codes and regulations.
4. Failure to locate the water heater in an area where leakage of the
tank or water line connections and the relief valve will not result in
damage to the area adjacent to the water heater or lower oors of
the structure.
5. Any failed components of the heat system not manufactured by
HTP as part of the water heater.
6. Water heaters repaired or altered without the prior written
approval of HTP.
7. Damages, malfunctions, or failures resulting from improper
installation, or failure to install the water heater in accordance
with applicable building codes/ordinances or good plumbing and
electrical trade practices; or failure to operate and maintain the water
heater in accordance with the manufacturer’s provided instructions.
8. Damages, malfunctions, or failures resulting from failure to operate
the water heater at pressures not exceeding the working pressure
shown on the rating label.
9. Failure to operate the water heater in an open system, or in a closed
system with a properly sized and installed thermal expansion tank.
10. Failure or performance problems caused by improper sizing of
the water heater, expansion device, or piping.
11. Damages, malfunctions, or failures resulting from vacuum
conditions.
12. Damages, malfunctions, or failures caused by operating the water
heater with modied, altered, or unapproved parts.
13. Damages, malfunctions, or failures caused by abuse, accident,
re, ood, freeze, lightning, acts of God and the like.
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 14
14
14. Failures (leaks) caused by operating the water heater in a corrosive
or contaminated atmosphere.
15. Failure of the water heater due to the accumulation of solid
materials and lime deposits.
16. Any damage or failure resulting from improper water chemistry.
WATER CHEMISTRY REQUIREMENTS (RESIDENTIAL USE) – Water pH
between 6.5 and 8.5. Operating temperatures not exceeding 140oF.
Hardness less than 12 grains (200 mg/L). Chloride concentration less
than 100 ppm (mg/L). TDS less than 500 ppm (mg/L). (COMMERCIAL
USE) - Water pH between 6.5 and 8.5. Hardness less than 7 grains (120
mg/L). Chloride concentration less than 100 ppm (mg/L). TDS less
than 500 ppm (mg/L).
17. Any damages, malfunctions, or failures resulting from the use of
dielectric unions.
18. Production of noise, taste, odors, discoloration, or rusty water.
19. Water heaters replaced for cosmetic reasons.
20. Components of the water heater that are not defective, but must
be replaced during the warranty period as a result of reasonable
wear and tear.
21. Damages, malfunctions, or failures resulting from the use of any
attachment(s) not supplied by HTP.
22. Water heaters installed outside the fty states (and the District of
Columbia) of the United States of America and Canada.
23. Water heaters moved from the original installation location.
24. Water heaters that have had their rating labels removed.
25. Water heaters used in steam boiler applications.
ONLINE EXTENDED RESIDENTIAL USE
LIMITED WARRANTY REGISTRATION
To register for the Extended Residential Use Limited Warranty,
complete the form and follow the payment instructions located on
the HTP website at www.htproducts.com/sspwarranty within 90
days of installation. The form must be completed in full with owner
name, email address, and phone number, the address where the unit
is installed and installation date, and unit model and serial numbers.
Proof of purchase is required, and may be an invoice for the product,
or a bill from an installing contractor that clearly documents the
installation of the unit. To be valid, proof of purchase must also
include the unit serial number. Proof of purchase may be typed or
hand written. Submit the proof of purchase and payment to HTP via
the directions provided on the website.
NOTE: When registration and purchase are complete, retain the
proof of Extended Residential Use Limited Warranty purchase.
Proof of Extended Residential Use Limited Warranty purchase must
be presented when making a warranty claim in order for Extended
Residential Use Limited Warranty to be valid.
PROCEDURES FOR WARRANTY SERVICE REQUESTS
Any claim for warranty assistance must be made promptly. Determine
if the water heater is “in-warranty” (that is, within the applicable
warranty period) by reviewing a copy of the original sales receipt or
warranty registration. The Owner must present a copy of the original
sales receipt or warranty registration for a warranty service request.
If the water heater is “in-warranty”, contact the retailer from whom
the water heater was purchased (or the installer) for assistance.
Be prepared to provide the retailer or installer with a copy of the
original receipt, complete model and serial numbers, and the date
of installation of the water heater, in addition to explanation of the
water heater problem.
Warranty coverage is subject to validation of “in-warranty” coverage
by HTP claims department personnel. All alleged defective or
malfunctioning components must be returned to HTP via the local
distribution channels where original purchase was made. NOTE: Any
components or heaters returned to HTP for warranty analysis will
become the property of HTP and will not be returned, even if credit
is denied. If all warranty conditions are satised, HTP will provide
replacement components to the retailer.
For questions about the coverage of this warranty, please contact HTP
at the following address or phone number: HTP, 272 Duchaine Blvd.,
New Bedford, MA, 02745, Attention: Warranty Service Department,
1(800) 323-9651.
SERVICE, LABOR AND SHIPPING COSTS
This limited warranty does not extend to any shipping charges,
delivery expenses, or administrative fees incurred by the Owner
in repairing or replacing the water heater or component(s). This
warranty does not extend to labor costs beyond the coverage
specied in this warranty document. All such expenses are the
Owner’s responsibility.
LIMITATIONS OF YOUR HTP WARRANTY AND REMEDIES
THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN
AND ACCEPTED TO THE FURTHEST EXTENT UNDER APPLICABLE
LAW IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE AND ANY OBLIGATION, LIABILITY, RIGHT,
CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT
ARISING FROM HTP’S NEGLIGENCE, ACTUAL OR IMPUTED. THE
REMEDIES OF THE OWNER SHALL BE LIMITED TO THOSE PROVIDED
HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES INCLUDING
WITHOUT LIMITATION, INCIDENTAL OR CONSEQUENTIAL
DAMAGES, SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES
INCLUDING, BUT NOT LIMITED TO, PROPERTY DAMAGE, LOST
PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY
ANY FAILURE OF HTP TO MEET ANY OBLIGATION UNDER THIS
AGREEMENT INCLUDING THE OBLIGATION TO REPAIR AND
REPLACE SET FORTH ABOVE. NO AGREEMENT VARYING OR
EXTENDING THE FOREGOING WARRANTIES, REMEDIES OR THIS
LIMITATION WILL BE BINDING UPON HTP. UNLESS IN WRITING
AND SIGNED BY A DULY AUTHORIZED OFFICER OF HTP. THE
WARRANTIES STATED HEREIN ARE NOT TRANSFERABLE AND
SHALL BE FOR THE BENEFIT OF THE OWNER ONLY.
NO OTHER WARRANTIES
This warranty gives you specic legal rights, and you may also have
other rights that vary from state to state. Some states do not allow
the exclusion or limitation of incidental or consequential damages so
this limitation or exclusion may not apply to you.
These are the only written warranties applicable to the water
heater manufactured and sold by HTP. HTP neither assumes nor
authorizes anyone to assume for it any other obligation or liability in
connection with said water heaters. HTP reserves the right to change
specications or discontinue models without notice.
lp-451 Rev. 001 Rel. 001 Date 7.25.17
Page 15
Customer Installation Record Form
The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After
reading the important notes at the bottom of the page, please also sign this document.
Customer’s Name
Date of Installation
Installation Address
Product Name / Serial Number(s)
Comments
15
Installer’s Code / Name
Installers Phone Number
Signed by Installer
Signed by Customer
IMPORTANT
Customer: Please only sign after the installer has fully reviewed the installation, safety, proper operation, and maintenance of the system. If
the system has any problems please call the installer. If you are unable to make contact, please call your sales representative.
Distributor / Dealer: Please insert contact details.
lp-451 Rev. 001 Rel. 001 Date 7.25.17
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