HTP SuperStor Ultra Indirect Fired Water Heaters User Manual

SuperStor Ultra

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

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

Indirect Fired

Water Heaters

INSTALLATION

START-UP

MAINTENANCE

PARTS

For Residential and Commercial Use

NOTICE: 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 consumable water contain less than 0.25% lead by weight, as required by the Safe Drinking Water Act, Section 1417.

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

LP-83 Rev. 3.24.14

The following defined 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 death or serious injury.

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

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

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

damage.

FOREWORD

This manual is intended to be used in conjunction with other literature provided with the SuperStor Ultra Indirect Fired Water Heater. This includes all related control information. It is important that this manual, all other documents included with 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 local code authorities and utility companies which pertain to this type of water heating equipment.

FOR THE INSTALLER

This water heater must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished with the water heater, and with 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 .......................................................................................................................... 3

A. PRECAUTIONS .......................................................................................................................................................................... 3

B. WHEN SERVICING THE WATER HEATING SYSTEM .............................................................................................................. 4

C. HEATER WATER ....................................................................................................................................................................... 4

D. FREEZE PROTECTION ............................................................................................................................................................. 4

E. CHEMICAL VAPOR CORROSION ............................................................................................................................................. 4

F. WATER TEMPERATURE ADJUSTMENT .................................................................................................................................. 5

PART 2 – PREPARE THE WATER HEATER ............................................................................................................................. 5

A. REDUCED BOILER INPUT SIZING GUIDE ............................................................................................................................... 8

B. PERFORMANCE AND SIZING GUIDELINES ................................................................................................ ............................ 9

C. LOCATING THE WATER HEATER ............................................................................................................................................ 9

D. WATER CHEMISTRY REQUIREMENTS ................................................................................................................................. 10

LP-83 Rev. 3.24.14

INSTALLER – Read all instructions in this manual before installing. Perform steps in the order given.

USER – This manual is for use only by a qualified heating installer/service technician. Have this heater serviced/inspected by a qualified service technician annually.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: If the heater is exposed to the following, do not operate until all corrective steps have been made by a qualified serviceman:

1. FIRE

2. DAMAGE

3. WATER Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

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.

PART 3 – HEATER PIPING ....................................................................................................................................................... 11

A. PLUMBING ............................................................................................................................................................................... 11

B. BOILER CONNECTIONS ......................................................................................................................................................... 11

C. DOMESTIC PIPING INLET ....................................................................................................................................................... 11

D. TEMPERATURE AND PRESSURE RELIEF VALVE................................................................................................................ 11

E. SCALDING ................................................................................................................................................................................ 12

F. POTABLE EXPANSION TANK ................................................................................................................................................. 13

G. PRESSURE DROP SIZING FOR CIRCULATOR ..................................................................................................................... 13

H. PIPING ...................................................................................................................................................................................... 14

PART 4 – HEATER CONTROL AND WIRING .......................................................................................................................... 23

A. CONTROL ................................................................................................................................................................................ 23

B. WIRING ..................................................................................................................................................................................... 23

C. WIRING DIAGRAMS ................................................................................................................................................................ 24

PART 5 – START-UP AND OPERATION.................................................................................................................................. 31

PART 6 – MAINTENANCE AND TROUBLESHOOTING .......................................................................................................... 33

HTP CUSTOMER INSTALLATION RECORD FORM...................................................................................................................... 35

PART 1 – GENERAL SAFETY INFORMATION

A. PRECAUTIONS

This water heater is approved for indoor installations only, and it 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 and 6” 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 flooring. 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.

LP-83 Rev. 3.24.14

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Failure of the water heater due to freeze related damage IS NOT covered by warranty.

In water heaters with single wall heat exchangers, the heat transfer fluid 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 fluid.

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 injury or death.

NOTE: OBTAIN ALL APPLICABLE PERMITS AND OBEY ALL LOCAL CODES. NOTE: Install all system components and piping in such a manner that does not reduce the performance of any fire rated assembly.

DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified service technician.

B. 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.

C. 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 “heater patent medicines”. Damage to 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:

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 (FDA).

2. The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system (steam systems must comply with this statement).

3. 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 Administrative Authority.

D. FREEZE PROTECTION

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

E. CHEMICAL VAPOR CORROSION

NOTE: DAMAGE TO THE WATER HEATER OR RELATED COMPONENTS CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. The limited warranty is voided when failure of water tank is due to a corrosive atmosphere. (Refer

to the limited warranty for complete terms and conditions).

LP-83 Rev. 3.24.14

PRODUCTS TO AVOID

AREAS LIKELY TO HAVE CONTAMINANTS

Spray cans containing fluorocarbons

Dry cleaning/laundry areas and establishments

Permanent wave solutions

Swimming pools

Chlorinated waxes/cleaners

Metal fabrication plants

Chlorine-based swimming pool chemicals

Beauty shops

Calcium chloride used for thawing

Refrigeration repair shops

Sodium chloride used for water softening

Photo processing plants

Refrigerant leaks

Auto body shops

Paint or varnish removers

Plastic manufacturing plants

Hydrochloric or Muriatic acid

Furniture refinishing areas and establishments

Cements and glues

New building construction

Antistatic fabric softeners used in clothes dryers

Remodeling areas

Chlorine-type bleaches, laundry detergents, and cleaning solvents

Garages and workshops

Adhesives used to fasten building products

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.

UNCRATING HEATER – Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

COLD WEATHER HANDLING – If the heater has been stored in a very cold location (BELOW 0oF) before installation, handle with care until the plastic components come to room temperature.

APPROXIMATE TIME / TEMPERATURE RELATIONSHIPS IN SCALDS

120oF

More than 5 minutes

125oF

1 ½ to 2 minutes

130oF

About 30 seconds

135oF

About 10 seconds

140oF

Less than 5 seconds

145oF

Less than 3 seconds

150oF

About 1 ½ seconds

155oF

About 1 second

Table 2

Table 1 – Chemical Contaminants

F. 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 temperature.

PART 2 – PREPARE THE WATER HEATER

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

LP-83 Rev. 3.24.14

Figure 1 – Dimensions

LP-83 Rev. 3.24.14

Figure 2 - Specifications CONTINUOUS FLOW PERFORMANCE CALCULATION

FIRST HOUR RATING – (.75 X TANK CAPACITY) = CONTINUOUS FLOW

EXAMPLE: SSU-45C = 314 – (.75 X 45) = 280.25

LP-83 Rev. 3.24.14

MODEL

GROSS OUT

BTU/HR

GROSS OUT

BTU/HR

GROSS OUT

BTU/HR

GROSS OUT

BTU/HR

GROSS OUT

BTU/HR

GROSS OUT

BTU/HR

GROSS OUT

BTU/HR

199,000

220,000

240,000

260,000

280,000

300,000

320,000

370

370 - - - -

SSU-60

266

266 - - - -

489

503

SSU-80

359

370

370 - 370

370

457

470

543

627

645

SSU-119

335

345

399

460

474

MODEL

2 GPM

2.5 GPM

3 GPM

3.5 GPM

4 GPM

4.5 GPM

5 GPM

9.5

8.0

7.0

5.5

4.5

4.0

3.5

SSU-20

8.5

7.5

6.5

5.0

4.0

3.5

3.0 A

16.0

13.0

10.0

7.5

6.0

5.5

5.0

SSU-30

14.0

12.0

9.0

7.0

5.5

5.0

4.5

18.0

14.0

12.0

9.0

6.5

6.0

5.5

SSU-30LB

17.0

12.0

10.0

8.0

6.0

5.5

5.0

23.0

18.0

14.0

11.0

8.5

7.5

7.0

SSU-45

18.0

15.0

13.0

10.0

7.5

6.5

∽ ∽ ∽

29.0

20.0

17.0

14.0

SSU-45C

45.0

24.0

26.0

18.0

16.0

13.0

10.0

∽ ∽ ∽

∽

36.0

30.0

22.0

SSU-60

∽ ∽ ∽

∽

29.0

19.0

12.0

∽ ∽ ∽ ∽ ∽

46.0

29.0

SSU-60C

B ∽ ∽ ∽ ∽ ∽ 30.0

21.0

∽ ∽ ∽ ∽ ∽ ∽ ∽

SSU-80

∽ ∽ ∽ ∽ ∽ ∽ ∽

SSU-80C

B ∽ ∽ ∽ ∽ ∽ ∽

∽ A

∽ ∽ ∽ ∽ ∽ ∽ ∽

SSU-119

∽ ∽ ∽ ∽ ∽ ∽ ∽

A ∽ ∽ ∽ ∽ ∽ ∽

∽

SSU-119C

B ∽ ∽ ∽ ∽ ∽ ∽

∽

A. REDUCED BOILER INPUT SIZING GUIDE

NOTE: IT IS NOT RECOMMENDED TO REDUCE BOILER INPUT WHEN USING DOUBLE WALL TANKS.

Table 3 – DESCRIBES COLD START FIRST HOUR RATINGS (A and B) AND BOILER SIZE 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 US gallon sizes. “C” commercial models for dual systems or commercial applications; use one coil for wood boiler, the other for oil boiler; adaptable to solar systems as

well; good for hotels, motels, and apartments. Models are available in the 45, 60, 80, and 119 US gallon sizes.

DETERMINE AMOUNT OF DOMESTIC HOT WATER NEEDED. THEN USE THE CHART BELOW TO OPTIMIZE SUPERSTOR ULTRA AND BOILER SIZING.

NOTE: FIRST DRAW AT 140oF at 90oF ΔT. (FOR PERFORMANCE AT 115oF, MULTIPLY BY 1.56 FOR MINUTES OF WATER DRAW.) LINE A GALLONS - LOW MASS BOILERS THAT TAKE LESS THAN 90 SECONDS TO HEAT TO TEMPERATURE LINE B GALLONS - HIGH MASS BOILERS THAT TAKE GREATER THAN 90 SECONDS TO HEAT TO TEMPERATURE

Table 4 - NOTE: THIS INFORMATION IS BASED ON BOILER SIZE CONFORMING TO THE MINIMUM BTU/H REQUIRED TO ACHIEVE FIRST HOUR RATINGS, OBTAINABLE FROM CHART ABOVE. ∽ - Indicates infinity (continuous duty).

LP-83 Rev. 3.24.14

MODEL

GROSS BOILER OUTPUT

140oF

90oF ΔT

127oF

77oF ΔT

115oF

65oF ΔT

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

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 floors of the building. The water heater should be located near a floor drain, or installed in a drain pan. HTP will NOT be held liable for leakage damages.

Ensure water heater location can support the entire filled weight of the tank. Failure to properly support the tank could result in property damage, serious personal injury, or death.

B. PERFORMANCE AND SIZING GUIDELINES

NOTE: TABLE 5 DESCRIBES MINIMUM BTU/H REQUIRED TO ACHIEVE THE LISTED FIRST HOUR RATING.

Table 5

C. LOCATING THE WATER HEATER

This water heater is certified for indoor use only. DO NOT INSTALL OUTDOORS. Outdoor installations ARE NOT covered by warranty. 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.

NOTE: To save on heating costs and improve energy efficiency, keep the distance between the boiler and water heater to a minimum to reduce heat loss from excess piping and keep friction loss to 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 flow 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 domestic hot water.

This water heater must be installed vertical on a level surface.

Figure 3 – Recommended Service Clearances

LP-83 Rev. 3.24.14

This water heater must not be located near flammable liquids such as gasoline, butane, liquefied 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.

Chemical imbalance of the water supply may affect efficiency and cause severe damage to the water heater 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 on both the domestic hot water and central heating sides are checked before installing the water heater, as water quality will affect the reliability of the system. Failure of a water heater due to lime scale build-up, low pH, or other chemical imbalance IS NOT covered by the warranty.

Operating temperatures above 135oF will further accelerate the build-up of lime scale and may shorten the service life of the water heater. Failure of the water heater due to lime scale build-up on the heating surface, low pH, or other chemical imbalance IS NOT covered by the warranty.

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 – 7.0

Hard

120 – 180

7.0 – 10.5

Very Hard

180 and over

10.5 and over

NOTE: If you do not provide the minimum clearances shown in Figure 3, it might not be possible to service the heater without removing it from the space.

D. WATER CHEMISTRY REQUIREMENTS

Outlined below are water quality parameters which need to be met in order for the system to operate efficiently 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 measurement used in the U.S. 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 classified 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 water heater. Operating temperatures above 135oF will further accelerate the buildup of lime scale and may shorten the service life of the water heater.

Water that is classified as hard and very hard must be softened to avoid water heater failure.

If the hardness of the water exceeds the maximum level of 7 grains per gallon, 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 affect water pH. The pH scale ranges from 0 to

14. Water with a pH of 7 is considered neutral. Water with a pH lower than 7 is considered acidic. Water 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 the warranty. The ideal pH range for water used in a water heater 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 total dissolved solids 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 a water heater.

The manufacturer of the water heater has no control over water quality, especially TDS levels in your system. Total dissolved solids in excess of 2,000 ppm will accelerate lime and scale formation on the element or heat exchanger. Water heater failure due to total

LP-83 Rev. 3.24.14

When filling 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.

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.

Use two wrenches when tightening water piping at 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 heater components.

Never use dielectric fittings or galvanized steel fittings on any domestic water connections. Use only copper or brass fittings. Failure to follow this caution will result in premature heater failure. Such failure is NOT covered by warranty.

dissolved solids in excess of 2,000 ppm is a non-warrantable condition. Failure of a water heater due to lime scale build up IS NOT

covered by the warranty. Hardness: 7 grains

Chloride levels: 100 ppm pH levels: 6-8 TDS: 2000 ppm

Sodium: 20 mGL

PART 3 – HEATER 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.

B. BOILER CONNECTIONS

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 flow direction. (See pressure drop sizing for circulator, this manual.) 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 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 the heat exchanger has steam or is slightly above the low water cut off.

NOTE: It is possible to use live steam in the heat exchanger of the SuperStor Ultra 80 and 119 residential and commercial models ONLY. Using any other Superstor Ultra model in live steam applications will result in product failure and VOID the warranty.

C. DOMESTIC PIPING INLET

Use both thread tape and pipe dope to connect an NPT brass tee. On the run, install a brass drain valve. In the branch, install an NPT male X ¾” (minimum) pipe adapter. A shut off valve between the city water supply and tank inlet is recommended for ease of service.

It may be recommended to use a back flow preventer – check local codes. If a back flow preventer or a 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 inlet pipe and hot water outlet pipes for the water heater.

D. TEMPERATURE AND PRESSURE RELIEF VALVE

On SSU-80 and SSU-119 residential and all commercial models, a ¾” temperature and pressure (T&P) port and relief valve are provided. On all other models, an appropriate T&P valve must be supplied and installed as described in Figure 4.

LP-83 Rev. 3.24.14

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