Page 1
RESIDENTIAL COMMERCIAL
HEAT TRANSFER PRODUCTS
INDIRECT FIRED WATER HEATERS
Heat Transfer Products, Inc., reserves the right to make product changes or updates without notice.
Heat Transfer Products will not be held liable for typographical errors in literature. For questions, please consult the factory.
Page 2
USING THIS MANUAL
2
DANGER
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION
CAUTION Indicates a potentially hazardous
situtation which, if not avoided, may result in
minor or moderate injury.
CAUTION
CAUTION used without the safety alert symbol
indicates a potentially hazardous situation which,
if not avoided, may result in property damage.
B. SPECIAL ATTENTION BOXES
Throughout this manual you will see these
special attention boxes to the right of this page
which are intended to supplement the
instructions and make special notice of
potential hazards. These categories are as
defined by the ANSI Z535.A Standard.
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in
this manual in the order shown. The order of
these instructions has been set in order to
provide the installer with a logical sequence of
steps that will minimize potential interferences
and maximize safety during heater installation.
Page 3
3
CUTAWAY ILLUSTRATION
INTRODUCING THE NEW SUPER-STOR ULTRA
SPECIFICATIONS AND PERFORMANCE RATINGS
ULTRA RESIDENTIAL SERIES
*DOE TEST METHOD BASED ON 90°F. TEMPERATURE RISE, 50°/140° 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.
LEDOM
SNOISNEMID
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*SGNITARRUOHTSRIF
.TH.AIDF°041F°511F°041F°511
02-USS"72"¼9102.TF.QS5180.6lag121lag861lag631lag581
03-USS"½93"¼9103.TF.QS5180.6lag451lag212lag271lag432
BL03-USS"½82"¼3203.TF.QS5180.6lag961lag432lag981lag752
54-USS"½25"¼9154.TF.QS02019.7lag212lag292lag732lag223
06-USS"½25"¼3206.TF.QS02019.7lag662lag073lag892lag504
08-USS"27"¼3208.TF.QS43211.9lag033lag044lag073lag305
911-USS"½37"72911.TF.QS43413.11lag324lag465lag474lag546
EZISKNAT
OTROOLF
RELIOB
YLPPUS
OTROOLF
RELIOB
NRUTER
OTROOLF
CITSEMOD
TUO
CITSEMOD
SNOITCENNOC
TSET
ERUSSERP
GNIKROW
ERUSSERP
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THGIEW
RELIOB081
EZIS/UTB
RELIOB002
EZIS/UTB
02-USS"9"½4"22ELAMTPN¾ISP003ISP051.SBL06000,48000,78
03-USS"9"½4"43ELAMTPN¾ISP003ISP051.SBL27000,201000,711
BL03-USS"9"½4"32ELAMTPN¾ISP003ISP051.SBL97000,411000,131
54-USS"9"½4"64ELAMTPN¾ISP003ISP051.SBL88000,141000,161
06-USS"9"½4"64ELAMTPN"1ISP003ISP051.SBL011000,471000,891
08-USS"92"6"¼96ELAMTPN"½1ISP003ISP051.SBL141000,212000,142
911-USS"¼03"¼7"66ELAMTPN"½1ISP003ISP051.SBL012000,962000,103
Page 4
4
SPECIFICATIONS AND PERFORMANCE RATINGS
*DOE TEST METHOD BASED ON 90°F. TEMPERATURE RISE, 50°/140° W/ BOILER WATER AT 180°F
NOTE: TANK RECOVERY FROM COLD START WILL BE BETWEEN 55-65 MINUTES WHEN SIZED WITH CORRECT FLOW
RATE, BOILER SIZE, AND PRESSURE DROP RATINGS FROM LIST IN ABOVE CHART.
* PRESSURE DROP RATING FOR SSU-45 AND SSU-60
6 GPM: 8.2'
7 GPM: 12.8'
** PRESSURE DROP RATING SSU-80DW AND SSU-119 DW
10 GPM: 13.6'
12 GPM: 15.9'
ULTRA COMMERCIAL SERIES
*DOE TEST METHOD BASED ON 90°F. TEMPERATURE RISE, 50°/140° 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.
LEDOM
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*SGNITARRUOHTSRIF
.TH.AIDF°041F°511F°041F°511
C54-USS24"¼3254.TF.QS04028.6lag413lag414lag153lag774
C06-USS"½25"¼3206.TF.QS04222.9lag453lag764lag693lag935
C08-USS"27"¼3208.TF.QS86420.01lag094lag746lag845lag547
C911-USS"½37"72911.TF.QS86827.21lag736lag148lag317lag079
EZISKNAT
OTROOLF
RELIOB
YLPPUS
OTROOLF
RELIOB
NRUTER
OTROOLF
CITSEMOD
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*SGNITARRUOHTSRIF
EZIS/UTB
RETAWRELIOB°002
*SGNITARRUOHTSRIF
EZIS/UTB
C54-USS"9"½4"53ELAMTPN"¾1ISP003ISP051.SBL99000,512000,642
C06-USS"9"½4"64ELAMTPN"1ISP003ISP051.SBL511000,542000,072
C08-USS"92"6"¼96ELAMTPN"½1ISP003ISP051.SBL141000,133000,473
C911-USS"¼03"¼7"66ELAMTPN"½1ISP003ISP051.SBL012000,524000,094
CONTINUOUS FLOW PERFORMANCE CALCULATION
FIRST HOUR RATING – (.75 x TANK CAPACITY) = CONTINUOUS FLOW
EXAMPLE: SSU-45C = 314 – (.75 x 45) = 280.25
(FHR) (CONTINUOUS FLOW)
*
*
**
**
MODEL
DIMENSIONS
CAPACITY
HEAT EXCH.
SURFACE
RECOMM.
FLOW RATE
PRESSURE
DROP (FEET)
180° BOILER WATER
FIRST HOUR RATINGS
180° BOILER WATER
2ND HOUR RATINGS
HT. DIA. 140°F 115°F 140°F 115°F
SSU-45DW 52 ½" 19 ¼" 45 20 SQ. FT. 10 7.9 70 GAL 108 GAL 40 GAL 63 GAL
SSU-60DW 52 ½" 23 ¼" 60 20 SQ. FT. 10 7.9 90 GAL 144 GAL 50 GAL 76 GAL
SSU-80DW 72" 23 ¼" 80 20 SQ. FT. 12 9.1 138 GAL 215 GAL 72 GAL 113 GAL
SSU-119DW 73 ½" 27" 119 20 SQ. FT. 14 11.3 210 GAL 326 GAL 110 GAL 171 GAL
TANK SIZE
FLOOR TO
BOILER
SUPPLY
FLOOR TO
BOILER
RETURN
FLOOR TO
DOMESTIC
OUTPUT
DOMESTIC
CONNECTIONS
TEST
PRESSURE
WORKING
PRESSURE
SHIPPING
WEIGHT
180° BOILER
BTU/SIZE
SSU-45DW 9" 4 ½" 46" ¾" NPT MALE 300 PSI 150 PSI 88 LBS. 107,000
SSU-60DW 9" 4 ½" 46" 1" NTP MALE 300 PSI 150 PSI 110 LBS. 176,000
SSU-80DW 29" 6" 69 ¼" 1 ½" NPT MALE 300 PSI 150 PSI 141 LBS. 208,000
SSU-119DW 30 ¼" 7 ¼" 66" 1 ½" NPT MALE 300 PSI 150 PSI 210 LBS. 231,000
Page 5
5
REDUCED BOILER INPUT SIZING GUIDE
NOTE: IT IS NOT RECOMMENDED TO REDUCE BOILER INPUT WHEN USING DOUBLE
WALL TANKS.
SUPERstor’s PRODUCT LINE CONSISTS OF VARIOUS MODELS, AVAILABLE IN DIFFERENT SIZES
CALL THE FACTORY FOR PRODUCT AND WARRANTY INFORMATION!
"DW" (double wall heat exchanger) models are available in the 45, 60, 80, and 119 U.S. gallon sizes
"CB" (coil booster) models operate in conjunction with a tankless heater, to increase hot water storage capacity. Models
are available in 30, 45, 60, 80, and 119 U.S. gallon sizes.
"C" commercial models for dual systems or commercial applications; use one coil for wood boiler, the other for the oil
boiler; adaptable to solar systems as well; also good for hotels, motels, and apartments. Models are available in the
45, 60, 80, and 119 U.S. gallon sizes.
TUOSSORG
RH/UTB
TUOSSORG
RH/UTB
TUOSSORG
RH/UTB
TUOSSORG
RH/UTB
TUOSSORG
RH/UTB
TUOSSORG
RH/UTB
TUOSSORG
RH/UTB
A———————
02-USS B———————
A———————
03-USS B———————
A———————
BL03-USS B———————
A———————
54-USS B———————
A073073073 ————
06-USSB662662662 ————
A984305305305305305—
08-USSB953073073— 073073—
A754074345726546546546
911-USSB533543993064474474474
MODEL 200,000 220,000 240,000 260,000 280,000 300,000 320,000
Page 6
6
PERFORMANCE AND SIZING GUIDELINES
DETERMINE AMOUNT OF DOMESTIC HOT WATER NEEDED, THEN USE THE CHARTS
BELOW TO OPTIMIZE SUPER STOR ULTRA V.S. BOILER SIZING.
COLD START BOILERS:
A. LESS THAN 90 SECONDS TO HEAT UP TO TEMPERATURE
B. GREATER THAN 90 SECONDS TO HEAT UP TO TEMPERATURE
NOTE: FIRST DRAW AT 140° F. (FOR PERFORMANCE AT 115° F, MULTIPLY BY 1.56 FOR
MINUTES OF WATER DRAW)
NOTE: THIS INFORMATION IS BASED ON BOILER SIZE CONFORMING TO THE MINIMUM
BTU/H REQUIRED TO ACHIEVE FIRST HOUR RATINGS, OBTAINABLE FROM CHART
ABOVE.
4 indicates infinity (continous duty)
LEDOMMPG0.2MPG5.2MPG0.3MPG5.3MPG0.4MPG5.4MPG0.5
A5.90.80.75.55.40.45.3
02-USSB5.85.75.60.50.45.30.3
A0.610.310.015.70.65.50.5
03-USSB0.410.210.90.75.50.55.4
A0.810.410.210.95.60.65.5
BL03-USSB0.710.210.010.80.65.50.5
A0.320.810.410.115.85.70.7
54-USSB0.810.510.310.015.75.75.6
A
444
0.920.020.710.41
C54-USSB0.540.420.620.810.610.310.01
A
44
44
0.630.030.22
06-USSB
4
444
0.920.910.21
A
44444
0.640.92
C06-USSB
44444
0.030.12
A
4444444
08-USSB
4444444
A
4444444
C08-USSB
4444444
A
4444444
911-USSB
4444444
A
4444444
C911-USSB
4444444
Page 7
7
LOCATION AND OPERATION
NOTE: MINIMUM BTU/H REQUIRED TO ACHIEVE FIRST HOUR RATING
LOCATION
Choose a location for your water heater centralized to the piping system. You must also
locate the Super Stor Ultra 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 certified as
an indoor appliance, and must also be kept vertical on a level surface.
OPERATING YOUR SUPER STOR ULTRA
“Boiler high limit should be at least 20° higher than the Super Stor Ultra 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. The differential should be 10° to 15°, if your control is adjustable, be
sure that it is in that range. We recommend a temperature setting of 119°F, or in accordance
with local and state codes for normal operation. You may prefer a setting of either higher or
lower temperature, to satisfy your needs. A mixing valve in connection with a high temperature setting may be used for high demand applications (spas, hot tubs, whirlpools)”
DANGER
This water heater must not be located near flammable liquids such as Gasoline,
Adhesives, Solvents, Paint Thinners, Butane, Liquefied Propane, etc.; as the controls
of this appliance could ignite vapors causing an explosion.
CAUTION
This unit 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 water heater should always
be located in an area with a floor drain or installed in a drain pan suitable for water
heaters. Heat Transfer Products Inc. shall not be held liable for any such water damage.
MODEL GROSS OUTPUT
140° F 90° F ∆T
GAL/HR
127° F 77° F ∆T
GAL/HR
115° F 65° F ∆T
GAL/HR
SSU-20 84,000 121 140 168
SSU-30 102,000 154 180 212
SSU-30LB 113,000 169 198 234
SSU-45 141,000 212 248 292
SSU-45C 215,000 314 367 414
SSU-60 174,000 266 311 370
SSU-60C 245,000 354 414 467
SSU-80 212,000 330 386 440
SSU-80C 331,000 490 573 647
SSU-119 269,999 423 495 564
SSU-119C 425,000 637 745 841
Page 8
8
PLUMBING
PLUMBING
It is mandatory that all plumbing is done is accordance with all local and state plumbing
codes, or warranty will be voided. It is also necessary on all mechanical connections, that
you use both thread tape and pipe dope.
NOTE: WHEN FILLING THE SUPER STOR ULTRA, MAKE SURE THAT YOU OPEN THE HOT
WATER TAP TO RELEASE AIR IN THE TANK AND PIPING.
BOILER CONNECTIONS
Use a 1" nominal minimum tube size, wherever you are using zone valves or circulators;
where a 1" zone valve and 1" tube is required.
On the tank, the boiler supply is to be connected to the outlet of the circulator. The inlet of
the circulator is to be connected to the “HOT OUTLET” side of the boiler. Be sure that the
arrow on the circulator is facing toward the flow direction, (See pressure drop sizing for circulator, page 8). On the tank, the boiler return is to be connected to the return side of the
boiler. The return(s) from heating loop(s) should have a flow check or swing check valve
installed before the return pipe from the tank.
In a steam boiler, the tank supply must be connected to the boiler, well below the minimum
water level. A strainer and a drain valve should be installed at the boiler for periodic draining of scale and sludge. Banging and steam bound traps will occur if the boiler water supplied to heat exchange has steam, or is slightly above the low water cut-out.
It is possible to use live steam in the heat exchanger of the Super Stor Ultra 80 and Super
Stor Ultra 119 only. Consult factory for suggested piping and required components. The
Ultra commercial series Super Stor Ultra 80C and Super Stor Ultra 119C are also included
in this application.
DANGER
Water temperature over 125° F. can cause severe burns instantly,
or death from scalds. Children, disabled, and elderly are at
highest risk of being scalded. See instruction manual before
setting temperature at water heater. Feel water before bathing
or showering! Temperature limiting valves are available.
WARNING
Never use dielectric unions or galvanized steel fittings on any domestic
water connections. Use only copper or brass fittings. Teflon thread
sealant must be used on all connections.
CAUTION
Risk of scald injury increases as you increase water temperature! If draining of the
SuperStor Ultra is necessary, open the T & P valve or a hot water tap, to prevent
vacuum buildup in the tank and piping.
Page 9
9
PLUMBING AND WIRING
COLD WATER INLET
Use both thread tape and pipe dope and connect an NPT brass tee. On the run, install a
brass drain valve. In the branch, install an NPT male X ¾ “ (minimum) tube adapter. A shut
off valve between city water supply and tank inlet is recommended for ease of service at a
later date. It may be recommended to use a back flow preventer – check your local codes
If a back flow preventer, or a return valve is not 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 inlet pipe and hot water
outlet pipes for the Super Stor Ultra tank.
DOMESTIC HOT WATER OUTLET CONNECTION
Use both thread tape and pipe dope, and connect an NPT brass tee. In the run of the brass
tee, install an NPT brass T & P valve long element, for hot water storage tanks (Required by
local codes, but not less than the valve certified as meeting the requirements for relief valves
for hot water heaters (ANSI Z212B-1984), by a nationally recognized lab that maintains periodic inspection of production listed equipment. Make sure that the relief valve is sized to the
BTU/Hour capacity and storage capacity of the water heater. The temperature and pressure
relief valve must be plumbed down so discharge can exit only 6” above, or at any distance
below the structural floor; and cannot be in contact with any live electrical parts.
CAUTION
DO NOT PLUG TUBE OUTLET IN TANKLESS COIL.
WARNING
Following installation of the T & P Relief Valve, the valve lever MUST be operated AT
LEAST ONCE A YEAR by the water heater owner to ensure that waterways are clear.
Certain naturally occurring mineral deposits may adhere to the valve, blocking
waterways, rendering it inoperative. When the lever is operated, hot water will
discharge if the waterways are clear. PRECAUTIONS MUST BE TAKEN TO AVOID
PERSONAL INJURY FROM CONTACT WITH HOT WATER AND TO AVOID PROPERTY
DAMAGE. BEFORE operating lever, check to see that a discharge line is connected to
the valve, directing the flow of hot water from the valve to a proper place of disposal. If
no water flows when the lever is operated, replacement of the valve is required. TURN
THE WATER HEATER “OFF” AND CALL A PLUMBER IMMEDIATELY.
This device is designed for emergency safety relief and shall not be used as an
operating control. A relief valve functions, in an emergency, by discharging water.
Therefore, it is essential that a discharge line be piped from the valve in order to carry
the overflow to a safe place of disposal. The discharge line must be same size as the
valve outlet must pitch downward from the valve and terminate at least 6" above a drain
where any discharge will be clearly visible.
Page 10
10
PLUMBING AND WIRING
(Optional to save additional energy dollars) In the bottom of the tee (branch) vertically down,
install an NPT tube adapter. Then install two sweat street 90° elbows. This acts as a thermal
loop to prevent thermal siphon action of hot water
EXPANSION TANK
A thermal expansion tank may be required in the system designed for potable water use, to
offset the expansion of stored water as the temperature is elevated (only in systems where
there is no return valve, a back flow preventer, a water meter, or anywhere pressure can
build up as the water is heated). See typical expansion tank on following page.
CONTROL
Install control element into well and tighten in place with screws on control body. Thermal
conductive paste is recommended. Once the control is operational, it is very important to
make sure the control is maintaining the desired operating temperature.
WIRING
All wiring is to be done in accordance with all applicable local and state codes. Turn off all
power related to the boiler starting and wiring procedures. It is recommended that a disconnect switch be installed between the boiler control and water heater.
CAUTION
REINSPECTION OF T&P RELIEF VALVES: Temperature and Pressure Relief Valves
should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced, if
necessary, by a licensed plumbing contractor or qualified service technician, to ensure
that the product has not been affected by corrosive water conditions and to ensure that
the valve and discharge line have not been altered or tampered with illegally. Certain
naturally occurring 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
continuing safety.
DANGER
WARNING: FAILURE TO REINSPECT THIS VALVE AS DIRECTED COULD RESULT IN
UNSAFE TEMPERATURE OR PRESSURE BUILDUP WHICH CAN RESULT IN SERIOUS
INJURY OR DEATH AND/OR SEVERE PROPERTY DAMAGE.
Page 11
11
PLUMBING AND WIRING
PRESSURE DROP SIZING FOR CIRCULATOR
You must have a flow rate, from chart on page 3, on the boiler circulator for the water; or
the published ratings cannot be achieved. The chart below represents the tube run and the
water heater ONLY, and does not include any flow checks or zone valves. That resistance
must be added to the value found in the chart below.
FOHTGNELEBUTROFPORDERUSSERP
EERGED09XISROFDNA,REPPOC"1
NUREHTNOEETNODNA,SWOBLE
EZISEBUT'02'03'04'05'06
MPG6'36.8'39.8'32.9'35.9'8.9
MPG7'3.11'77.11'42.21'7.21'1.31
MPG01'52.01'1.11'59.11'8.21'66.31
MPG21'3.11'2.31'1.41'51'61
MPG41'3.51'4.61'5.71'6.81'8.91
MPG41'3.51'4.61'5.71'6.81'8.91
FOHTGNELEBUTROFPORDERUSSERP
SEET2DNASWOBLE°09NET,REPPOC"¼1
EZISEBUT'02'03'04'05'06
MPG02'9.01'7.11'6.21'4.31'3.41
MPG22'0.41'0.51'0.61'0.71'0.81
MPG42'2.61'5.71'8.81'1.02'5.12
MPG82'4.02'0.226.322.528.62
Page 12
12
TYPICAL INSTALLATIONS
TYPICAL INSTALLATION USING ZONE VALVES
TYPICAL EXPANSION TANKTYPICAL MIXING VALVE
Page 13
13
TYPICAL INSTALLATIONS
TYPICAL INSTALLATION USING CIRCULATORS
TYPICAL INSTALLATION USING A ZONE VALVE (3-WAY)
Page 14
14
TYPICAL INSTALLATIONS
TYPICAL DP INSTALLATIONS
SUPERSTOR WITH STORAGE TANK TYPICAL INSTALLATION
Page 15
15
TYPICAL INSTALLATIONS
MULTIPLE TANK INSTALLATIONS
TYPICAL STEAM BOILER
Page 16
16
WIRING DIAGRAMS
ZONING WITH CIRCULATORS WITH R845 RELAY
ZONING WITH CIRCULATORS USING R8182D AND D.P.S.T. NO RELAY REQUIRED
Page 17
17
WIRING DIAGRAMS
ZONING WITH CIRCULATORS USING L8124 A, C AND R845A RELAY
ZONING WITH CIRCULATORS USING L8124 E,F AND D.P.S.T. CONTROL. (NO RELAY REQUIRED)
Page 18
18
WIRING DIAGRAMS
ZONING WITH CIRCULATORS WITH R182D AND R845A RELAY
USING CONTROL WITH BUILT IN IDPST SWITCH WITH NO RELAY REQUIRED
Page 19
19
WIRING DIAGRAMS
ZONING WITH CIRCULATORS USING L8124 A, C AND R845A RELAY
ZONING WITH CIRCULATORS USING L8124 A,C AND D.P.S.T. (NO RELAY REQUIRED)
Page 20
20
WIRING DIAGRAMS
USING L8148A OR L8152A COLD START BOILER CONTROL WITH CIRCULATORS
PRIORITY ZONE WITH CIRCULATORS
Page 21
21
WIRING DIAGRAMS
USING L8148A OR L8152A COLD START BOILER CONTROL WITH ZONE VALVES
PRIORITY ZONE WITH ZONE VALVES
Page 22
22
TROUBLESHOOTING
TROUBLESHOOTING YOUR SUPER STOR ULTRA
NO HOT WATER
NOT ENOUGH HOT WATER
T & P VALVE DISCHARGES
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23
HOT TUBS, SPAS, MULTIPLE SHOWERS, HIGH DEMAND
TROUBLESHOOTING
WARNING
When raising tank temperature, you increase the risk of scalding – Please use a water
tempering or mixing valve and extreme caution. Consult codes for conformance.
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© Copyright 2006, 2005 Heat Transfer Products, Inc. LP-83 REV. 1/1/06
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