Heat Transfer SUPERStor SSC-80 Operating Manual

SUPERStor
CONTENDER
INDIRECT FIRED WATER HEATERS
m|
Manufactured by:
508-763-8071
HEAT TRANSFER PRODUCTS, INC
120 BRALEY ROAD
P.O. BOX 429
EAST FREETOWN, MA 02717 U.S.A.
http://www.htproducts.com LP-65 REM.: 6/1/01

INTRODUCING THE NEW SUPER-STOR
CONTENDER
2" Polyurethane foam insulation
on outside; le_than lf2" F per
hour heat loss(R17)
Plastic jad(e
FLOOR
Boiler supply 1" NPT
Drain Valve factory installed
_'_IT=L'iD]_[_7_[e]_ _1_ __[e]_ I;_e_ _]
HEAT EXCHANGER HEAT EXCHANGER
DIMENSIONS CAPACITY HEAT EXCH. RECOMMENDED. PRESSURE FIRST HOUR RATINGB*
MODEL PIT. DIA. (US GALLONS) PRIME SURFACE FLOW RAT_ DROP(FEET) 140_F 115"F
SSC-50 45 _23' 50 7.5 Squar_ Feet 8 GPM 2.0 145 200
SSC-80 67' 23' 80 7.5 Square Feet 10 GPM 3.2 185 251
SSC-119 67" 27' 119 7.5 Square Feet 12 GPM 49 280 386
*DOE TEST METHOD BASED ON 90=F. TEMPERATURE RISE, 55°/145 °W/BOILER WATER AT 180°F
FLOOR TO FLOOR TO FLOOR TO FLOOR TO
BOILER BOILER DOMESTIC DRAIN DOMESTIC TEST WORKING SHIPPING
TANK SIZE SUPPLY RETURN OUT VALVE CONNECTIONS PRESSURE PRESSURE WEIGHT
SSC-50 6" 24 ° 46" 4' 3/4' NPT MALE 300 PSI 150 PSI 160
SSC-80 6' 24' 69" 4" 1 1/2"NPT MALE 300 PSI 150 PSI 214
SSC-119 61/2' 24 1/2' 69 °4" 1 1/2" NPT MALE 300 PSI 150 PSI 294
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. THE MASS OF THE BOILER WILL EFFECT RECOVERY
TIME, MORE BOILER MASS EQUALS LONGER RECOVERY TIME.
"DW"
"CB"
"DP"
.U.
SUPERstor's PRODUCT UNE CONSISTS VARIOUS MODELS, AVAILABLE IN DIFFERENT SIZES CALL THE FACTORY
FOR PRODUCT AND WARRANTY INFORMATION!
(doubal wall heat exchanger) models are avallabal in the 40, 60, 80, and 119 U.S. gallon sizes
(coil booster) models operate in conjunction with a tankless heater, to increase hot water storage
capacity, Models are avallsble In 30, 40, 60, 80, and 119 U.S. gallon sizes,
(dual p_trpose) models for dual systems or commercial applications; use one COilfor wood boiler, the other for the oil boiler; adaptabal to solar
systems as well; also good for hotels, motels, and apartments, Models are avallabal in the 40, 60, 80. and 119 US gelIc_ sizes¸
(ultra) high output stainless steel; the ultimate indirect, best available, worldwide,
_SEE THE ENGINEERING & SPECIFICATION MANUAL FOR COMPLETE COMMERCIAL LINE & SIZING GUIDEI
LP-65 PAGE: 1 REV.: 6/1/01

DETERMINE AMOUNT OF DOMESTIC HOT WATER NEEDED, THEN USE THE CHART BELOW TO OPTIMIZE SUPER STOR
CONTENDER V.S. BOILER SIZING.
NOTE: MINIMUM BTU/H REQUtRED TO ACHIEVE FIRST HOUR RATING THE MASS OF THE BOILER WILL
EFFECT RECOVERY TIME, MORE BOILER MASS EQUALS LONGER RECOVERY TIME.
NOTE:
GROSS 140° F 127 °F 115°F
MODEL OUTPUT 90° F. AT 77 ° F. AT 65 °F. AT
SSC-50 83,000 145 GAL/HR 170 GAiJHR 200 GAL/HR
SSC-80 110,000 185 GAL/HR 218 GAL/HR 251 GAL/HR
SSC-119 154,000 280 GAL/HR 330 GAL/HR 386 GAIJHR
ABOVE CHART IS BASED ON BOILER SIZE CONFORMING TO THE MINIMUM BTU/H REQUIRED TO
ACHIEVE FIRST HOUR RATINGS, OBTAINABLE FROM CHART ABOVE. THE MASS OF THE BOILER
WILL EFFECT RECOVERY TIME, MORE BOILER MASS EQUALS LONGER RECOVERY TIME.
REDUCED BOILER INPUT, SIZING GUIDE
115°F 65° t_T 140°F 90 °t_T
GROSS OUT FIRST HOUR RATING FIRST HOUR RATING
B.T.U.H. GALLONS GALLONS
SSC-50
20,000 77 56
40,000 115 83
60,000 152 110
80,000 200 145
100,000 200 145
120,000 200 145
SSC-80
20,000 97 71
40,000 135 98
60,000 173 125
80,000 245 178
100,000 251 185
110,000 251 185
120,000 251 185
SSC-119
40,000 176 128
60,000 214 155
80,000 252 182
108,000 288 208
120,000 325 235
140,000 360 261
154,000 386 280
160,000 386 280
LP-65 PAGE: 2 REVo:6/1/01

LOCATION
Choose a location for your water heater centralized to the piping system. You must also locate the Super Stor Contender 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
accessed. This appliance must not be installed outdoors, as it is certified as an indoor appliance, and must be kept vertical and on a level
surface. [IMPORTANT CAUTION: Care must be exercised when choosing the location of this appliance, 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. Under no circumstances, shall Heat Transfer Products Inc. be held liable for any such water damage whatsoever. This
water heater must not be located near flammable liquids such as Gasoline, Adhesives, Solvents, Paint Thinners, Butane. Liauefied
Propane, etc.i as the controls of this appliance could iqnite those vapors causlnq an explosion.
OPERATING YOUR SUPER STOR CONTENDER
Boiler high limit should be at least 20°higher than the Super Stor Contender 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.
We recommend a temperature setting of 119°F, or in accordance with local and state codes for normal operation. The differential is fixed
at 3°-5 °. You may prefer a setting of either higher or lower temperature, to satisfy your needs. A mixing valve in conjunction with a high
temperature setting may be used for high demand applications (spas, hot tubs, whirlpools)
NOTE: RISK OF SCALD INJURY INCREASES AS YOU INCREASE WATER TEMPERATURE! IF
DRAINING OF THE SUPER STOR CONTENDER IS NECESSARY, OPEN THE T & P VALVE
OR A HOT WATER TAP, TO PREVENT VACUUM BUILD UP IN THE TANK AND PIPING.
PLUMBING
It is mandatory that all plumbing isdone 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 beth thread tape and pipe dope.
NOTE: WHEN FILLING THE SUPER STOR CONTENDER, MAKE SURE THAT YOU OPEN THE HOT
WATER TAP TO RELEASE THE AIR IN THE TANK AND PIPING.
BOILER CONNECTION,'
Use a1" nominal minimum tube size, where you are using zone valves or cimulators; 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 5). 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
the heat exchanger has steam, or is slightly above low water cut-out.
COLD WATER INLET
Use both thread tape and pipe dope and connect a NPT male X3_. (minimum) tube adapter. [IMPORTANT CAUTION: Dielectric fittings
must be used.] A shut off valve between city water supply and tank inlet is recommended for ease of service at a later date. [IMPORTANT
CAUTION: Exercise extreme caution when soldering, due to the plastic dip tube on beth the hot water outlet and cold water inlet.] It may be
recommended to use a back flow preventor- check your local codes. If a back flow preventor, 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 Super Stor Contender tank. DO NOT PLUG TUBE
OUTLET IN TANKLESS COIL.
LP-65 PAGE: 3 REV.: 6/1/01

IDANGER?
\
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, see manual.
TEMPERATURE AND PRESSURE RELIEF VALVE
Afactory installed 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 of listed equipment, has been installed for your safety and convenience. If servicing, make sure that the relief valve is
sized to the BTU/Hour capacity and storage capacity of the water heater. The tam_erature and Dreesure relief valve must be Dlumbed
down so dischatae can exit only 6" above, or at any distance below the structural floor: and cannot contact any live electrical parts.
If the relief valve weeps, see expansion tank section for suggestions+
HOT WATER OUTLET
Use beth thread tape and pipe dope and connect a NPT male X _Y4"(minimum) tube adapter. A shut off valve between hotwater supply and
tank outlet is recommended for ease of se_,ice at a later date. [IMPORTANT CAUTION: Dielectric fittings must be used.] [IMPORTANT
CAUTION: Exercise extreme caution when soldedng, due to the plastic dip tube on both the hot water outlet and cold water inlet.]
[IMPORTANT CAUTION: A temperature limiting valve or mixing valve is not entirely necessary. Extreme caution on scalding is recommended
if a temperature limiting or mixing valve is not used. See note above.]
CONTROL
A surface mounted control is provided and mounted inside of the control access compartment. There isa insulation blanket under the control
access cover, to insure accurate readings of actual water temperature. The control isfactory set at 118° for your safety (see "DANGER"
above). The differential is fixed at 3 ° to 5°, (not adjustable).
WIRING
All widng is to be done in accordance with all applicable local and state codes. Tum off aft power related to the boiler starting and wiring
procedures. See pages 9 and 10. It is recommended that a disconnect switchbe installed between the boiler control and water heater.
EXPANSION TANK
A thermal expansion tank for hot potable water, may be required and necessary, to offset the expansion of the water as it is heated. If there is
abeck flow preventor, or any other type of no return valve or check valve, the thermal expansion tank is mandatory. The expansion tank must
be sized for the entire water volume of the hot water system. A indication of a required expansion tank, is a weeping relief valve. See Typical
Expansion Tank on page 5.
LP-65 PAGE: 4 REV.: 6/1/01

PRESSURE DROP SIZING FOR CIRCULATOR
You must have a flow rate, from chart, on the boiler circulatorfor the boiler water; or the published ratings cannot be achieved. The chart
below represents the tube run and the water heater, heat exchanger ONLY, and does not include any flow checks or zone valves or friction
loss through the boiler.
PRESSURE DROP FOR TUBE LENGTH OF 1" COPPER,
AND FOR SIX 90 DEGREE ELBOWS, AND ON TEE ON THE RUN
TUBE SIZE 20' 30' 40' 50' 60'
SSC-50 8 GPM 3.71 4.28 4.85 5.42 6
SSC-80 10GPM 5.75 6.6 7.45 8.3 9.15
SSC-119 12GPM 8.2 9.3 10.4 11.5 12.6
I11
HOT _ COLD
SUPER-STOR
CONTENDER
indirect fired
NOTE: RECClMENDED MXING VALVE IS SHOWN
SEE HOT WATER OUTLET ON PAGE 4
o
LINE
R_ BRASS BACK FLOW
RELIEF RETURN VALVE
LlI,,",]l_[e]P:,(oliL_|IW"J[_,.qI _'_J_I I-'vl
tIT IS RECOMMENDED THAT 't" UNES AND A 't"ZONE VALVE ARE USED FOR SUPER STORDONTENDERZONErl R
NOT T POlO _
-- Lj ,i,NPT TO t' StJVEAT COUPLIN<)
NOTE: IF ABACK FLOW PREVENTER OR A NO RETURN VALVE IS INSTALLED, A THERMAL E.X.PAN SION TANK IS
REQUIRED ON THE COLD WATER INLET BETWEEN THE SUPER STORE CONTENDER AND THE BAEKFO'dtt
PREVENTER.
LP-65 PAGE: 5 REV.: 611/01

TYPICAL INSTALLATION USING CIRCULATORS
HOTT [COLD
SUPER STOR
CONTENDER
Indire_Fired
Tank
IT IS RECOMMENDED THAT 1" LINES
ARE USED FOR SUPER STORZONE.
_ LONG ELEMENT
T&PVALVE
ITANK
CIRCULATOR
24v._iring
I
C
BOILER - ' l i
T
CONTROL
III _) 110v. wiringl_}
LRNPT TO I"SWEAT COUPLINP° I BOILER I
AIN RETURN
NOTE: RECOMENDED MXING VALVE IS SHOWN
SEE HOT WATER OUTLET ON PAGE 4.
NOTE: IF A BACKFLOW PREVENTER OR A NO RETURN VALVE IS INSTALLED. A
THERMAL EXPANSION TANK IS REQUIRED ON THE COLD WATER INLET
BETWEEN THE SUPER STOR AND THE BACKFLOW PREVENTER,
TYPICAL INSTALLATION USING A ZONE VALVE (3-WAY)
HOT IIcoLO
SUPER STOR
CONTENDER
Indite ot Fired
Tank
_rL iii
;.PT AIN
IT IS RECOMMENDED THAT 1" LINES
ARE USED FOR SUPER STOR ZONE.
_d LONG ELEMENT
T&P VALVE
II
TAN K
CIRCULATOR
24 v. wiring BOILER - _' I I
CONTROL
TO t" SWEAT COUPLING BOILER
RETURN
110 v. ,.,_irinq
i{ !)
I
NOTE: IF A BACKFLOW PREVENTER OR A NO RETURN VALVE IS INSTALLED, A
THERMAL EXPANSION TANK IS REQUIRED ON THE COLD WATER INLET
BETWEEN THE SUPER STOR AND THE BACKFLOW PREVENTER.
LP-65 PAGE: 6 REV.: 611/01

SUPER STOR CONTENDER WITH STORAGE TANK
TYPICAL INSTALLATION
COLD
WATER
SUPPLY
HOTTO 1._ [
_ CB OR GL
stT°=''"g' it,nk-_'-_.
inlet _-E valve
I¢lrculltor
8. drain
iT T I COLD 1TRI_ u_EECDOFMo_NuDpE_RT_TAOT;_INES
Ill OONTRQL," v,.,°0
._.___pDRA,. t _ I
NOTE: IF A SACKFLOW PREVENTER OR A NO RETURN VALVE IS INSTALLED, A
THERMAL EXPANSION TANK IS REQUIRED ON THE COLD WATER INLET
BETWEEN THE SUPER STOR AND THE BACKFLOW PREVENTER.
MULTIPLE TANK INSTALLATIONS
COLD i
WATER II II
SUPPLY hi
/
HOT i' J COLD HOT T _COLD
H
CONTENDER CONTENDER
Indireot Fired Indireot Fired
Tank Tank
OO,LP Ill I Ill
cT'_NKRoLS
II iTO
H°T
FIXTURES
HOT COLD
SUPER STOR
CONTENDER
In dire t-'t Fired
Tank
J
TANK
CONTROL:
ELEMENT
T_,,P
VALVE
NOTE: ALL PIPING IN PARALLEL USED FOR LARGE DUMPS
OF HOT WATER; HIGH USAGE, SHORT DURATION.
LP-65 PAGE: 7 REV.: 6/1/01

WATER LINE
CONDENSATE
RETURN
I
TYPICAL STEAM BOILER
SYTEM SUPPLY
HI
HOT T I SOLO
I
STEAM BOILER
D
Indirect Fire
STR._JN ER l _._T ank
,d
qLONG ELEMENT
_T & PVALVE
=_DRAIN
NOTE: WATER LINE MUST REMAIN ABOVE BOILER
OUTLET TO WATER HEATER AT ALL TIMES!
LP-65 PAGE: 8 REV.: 6/1/01

LzIOOO
TANK
ZONING WITH CIRCULATORS USING R8182D AND R845A RELA_
RB'iE2B
N84_A
TANK CIRCULATOR
:B.EW
;CONTACT_
J_l, 120 Vac POWER SUPPLY PROVIDE
DISCONNECT MEANS AND OVERLOAD _I
PROTECTION AS REQUIRED. TO ADDITIONAL
THERMOS;TAT HEAT ANTICIPATOR ZONES 3.4. ETC.
BETTtNG 0.2 AMP FOR RBtE2D. 4_
j_THERMO_TAT HEAT ANTICIPATOR B_TTINO O.4AMP
FOR RB45A 24 VOLT
THERMOSTAT
_CONTROL CASE M_JST BE CONNECTED TO EATH
GROUND. USED GROUNDING ECRE',J_ PROVIf_EB.
TO OIL
BURNER
.AND
._ IGNITION
TO WATER
CfRCULATOR
ZONING WITH CIRCULATORS USING L8124 E-F AND R845A RELA_
TO ADOITIONAL
RB4_SA RELAYS
4" _' FOR OTHER ZONEr
L2 Lt R 84_ A
TANK
CONTROL
TANK
CIRCULATOR
LOW VO LTAG I::
GAS VALVE
,_ POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECWON AS REQUIRED
LP-65 PAGE: 9 REV.: 6/1/01

_lJl_tl_l) Im]r_4[_7.,_Lv_[,."]
USING L8148A OR L8152A COLD START BOILER CONTROL WITH CIRCULATORE
TO ADDITIO NAL
POWER
SUPPLY
1 L2
:iTt
LOW _
LIMIT
CONTROL _
9@0(
CIRCULATOR
APROVIDE DISCONNECT MEANS AND
OVERLOAD PROTECTION AS REQUIRED
I
USING L8143A OR L8152A COLD START BOILER CONTROL WITH ZONE VALVE-'=
ZONE VALVE WIRING (24 VOLT) POWER
SUPPLY
LI 1.2
(HOT)
I
C,RCU 'TOR
5UPER STOR
CONTENDER
TANK
N---
CONTROL
,4_ PROVIDE DISCONNECT
MEANS AND OVERLOAD
PROTECTION AS REQUIRED
,_ WHEN USING LOW LIMIT
CIRCULATOR CONTROL REMOVE
LI-3 JUMPER
_RHOORMMOSTAT
SIDE TRANSFORMER
24V Ir_-_ PRIMARY
A.C SIDE
60 CYCLES [ I ,:_ _:: 1 110 V OR
22oVA.C.
B0 CYCLES
ZONE VALVE
LP-65 PAGE: 10 REV.: 6/1/01

NO HOT WATER
PROBLEM:
A. ZONE VALVE NOT OPENING
B. CIRCULATOR NOT OPERATING
C. TANK CONTROL SET TOO LOW
D. BOILER CONTROL SET TOO LOW
E. WIRING INCORRECT
F. TANK CONTROL FAILURE
G. ZONE VALVE FAILURE
H. CIRCULATOR FAILURE
I. AIR TRAP IN LOOP
POSSIBLE SOLUTION
A. OPEN MANUALLY TO CHECK
B. CHECKOR REPLACE
C. ***RAISE TANK TEMPERATURE_SEE IMPORTANT NOTE BELOW)
D. RAISE BOILER TEMPERATURE
E. RECHECK WIRING
F. REPLACE CONTROL
G. REPLACE VALVE
H. REPLACE CIRCULATOR
I. PURGE TO REMOVE AIR
NOT ENOUGH HOT WATER
PROBLEM:
A. ZONE VALVE RESTRICTION
B. CIRCULATOR ARROW REVERSED
D. BOILER TEMPERATURE TOO LOW
E. BOILER SIZED TOO SMALL
F. DEMAND FLOW RATE TOO HIGH
G. TANK SIZED TOO SMALL
H. DEMAND FLOW RATE TOO HIGH
I. AIR TRAP IN LOOP
J. HEAT & TANK COME ON TOGEATHER
K. NOT ENOUGH SPACE HEAT
L. SLOW RECOVERY
POSSIBLE SOLUTION
A. 1" FULL BORE REPLACE ZONE VALVE
B. REVERSE CIRCULATOR
D. RAISE BOILERTEMPERATURE
E. CHECK SIZING CHART
F. CHECK SIZING CHART
G. CHECK SIZING CHART
H. INSTALL MIXING VALVE, ***RAISE TANK TEMP (SEE NOTE BELOW)
INSTALL FLOW REGULATOR
L PURGE TO REMOVE AIR
J. RE-CHECK WIRING OR COINCIDENCE
DRAW TANK DOWN AND LOWER HEAT THERMOSTAT. RE-CHECK
K. BOILER SIZED TOO SMALL, CONSULT CHART
L. CIRCULATOR HEAD CAPACITY TOO LOW
T & P VALVE DISCHARGES
PROBLEM:
A. TANK TEMPERATURE TOO HIGH
B, WATER EXPANDS WHEN HEATED
C, WATER PRESSURE TOO HiGH
POSSIBLE SOLUTION
A. LOWER TEMPERATURE ON TANK
B. INSTALL EXPANSION TANK
C. INSTALL PRESSURE REDUCING VALVE
HOT TUBS_ SPAS rMULTIPLE SHOWERS THIGH DEMAND
PROBLEM:
A. NOT ENOUGH HOT WATER
B. PRESSURE TOO LOW
C, RECOVERY OF TANK SLOW
D. NOT ENOUGH HOT WATER
POSSIBLE SOLUTION
A. CHECK FLOW RATE AND COMPARE TO CHART
B. CHECK LINE PRESSURE FOR RESTRICTION
C. SLOW START UP BOILER, SEE CHART
D. BOILER SIZED TOO SMALL, SEE CHART
DEMAND TOO GREAT, CHECK FLOW RATES AND COMPART TO CHART.
INSTALL MIXING VALVE AND OR A FLOW RESTRICTING ALVE AND ***RAISE
TANK AND BOILER TEMPERATURE (SEE NOTE BELOW).
***NOTE: WHEN RAISING TANK TEMPERATURE, YOU INCREASE THE RISK OF SCALDING -PLEASE USE A |
i
WATER TEMPERING OR MIXING VALVE AND EXTREME CAUTION. CONSULT CODES FOR |
ICONFORMANCE. SEE PAGE 7. FOR EXAMPLE,
MANUFACTURED BY:
HEAT TRANSFER PRODUCTS, INC.; P.O. BOX 429, 120 BRALEY ROAD; EAST FREETOWN, MA 02717; 1-800-323-9651
OR VISIT OUR WEBSITE: WY_N.HTPRODUCTS.COM
LP-65 PAGE: 11 REV.: 6/1/01