HTP Superstor GL-50 User manual

120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com
LP-181 Rev. 3.25.14
SuperStor
Glass Lined
Storage Tank
INSTALLATION
MAINTENANCE
TROUBLESHOOTING
PARTS
Storage Tank Models
GL-50 / GL-80*
GL-119* / GL-175*
For Residential and Commercial Use
*Available in Metal Jacketed ASME and Non-ASME
models
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.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing.
Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.

2
LP-181 Rev. 3.25.14
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 Glass Lined Storage Tank. 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 domestic hot water storage equipment.
FOR THE INSTALLER
This storage tank must be installed by qualified and licensed personnel. The installer should be guided by the instructions furnished
with the storage tank, 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..............................................................................................................3
PART 2 –PREPARE THE STORAGE TANK..............................................................................................................................4
A. SPECIFICATIONS AND PERFORMANCE RATINGS................................................................................................................4
B. LOCATING THE STORAGE TANK.............................................................................................................................................5
C. OPTIONAL EQUIPMENT ...........................................................................................................................................................5
D. WATER CHEMISTRY REQUIREMENTS...................................................................................................................................5
This manual must only be used by a qualified heating installer/service technician. Read all instructions in this manual before installing.
Perform steps in the order given. Failure to comply could result in substantial property damage, severe personal injury, or death.

3
LP-181 Rev. 3.25.14
PART 3 –PIPING .........................................................................................................................................................................6
A. PLUMBING .................................................................................................................................................................................6
B. TANKLESS COIL CONNECTIONS.............................................................................................................................................6
C. HOT WATER OUTLET...............................................................................................................................................................7
D. TYPICAL INSTALLATION ..........................................................................................................................................................8
E. POTABLE EXPANSION TANK...................................................................................................................................................8
PART 4 –CONTROL AND WIRING............................................................................................................................................8
A. CONTROL ..................................................................................................................................................................................8
B. WIRING.......................................................................................................................................................................................8
PART 5 –OPERATING THE STORAGE TANK..........................................................................................................................9
PART 6 –MAINTENANCE AND TROUBLESHOOTING..........................................................................................................10
HTP CUSTOMER INSTALLATION RECORD FORM ......................................................................................................................12
PART 1 –GENERAL SAFETY INFORMATION
A. PRECAUTIONS
This storage tank is approved for indoor installations only. Clearance to combustible materials: 0” top, bottom, sides and back. Tank
must have room for service: 24” front and 6” sides are minimum recommended service clearances. (A combustible door or removable
panel is acceptable front clearance.) This storage tank has been approved for closet installation, and installation on combustible
flooring. Do not install this storage tank directly on carpeting.
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 storage tank 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.
DO NOT USE THIS STORAGE TANK IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified service technician.
NOTE: If the storage tank 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.
B. WHEN SERVICING THE WATER HEATING SYSTEM
To avoid electric shock, disconnect electrical supply before performing maintenance.
To avoid severe burns, allow all related water heating equipment to cool before servicing.
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.

4
LP-181 Rev. 3.25.14
PART 2 –PREPARE THE STORAGE TANK
UNCRATING STORAGE TANK –Any claims for damage or shortage in shipment must be filed immediately against the transportation
company by the consignee.
COLD WEATHER HANDLING –If the storage tank has been stored in a very cold location (BELOW 0oF) before installation, handle
with care until the plastic components come to room temperature.
Remove all sides of the shipping crate to allow the storage tank to be moved into its installation location.
A. SPECIFICATIONS AND PERFORMANCE RATINGS
Figure 1 –Specifications and Dimensions

5
LP-181 Rev. 3.25.14
B. LOCATING THE STORAGE TANK
This storage tank is certified for indoor use only. DO NOT INSTALL OUTDOORS. Outdoor installations ARE NOT covered by warranty.
Choose a location for the storage tank as centralized to the piping system as possible. Also, locate the storage tank and domestic water
piping where it will not be exposed to freezing temperatures. All piping should be insulated. Additionally, place the storage tank so that
the drain, controls, and inlets/outlets are easily accessible.
This storage tank must be installed vertical on a level surface.
Locate the storage tank where any leakage from the relief valve, related piping, tank, or connections will not result in damage to
surrounding areas or lower floors of the building. The storage tank should be located near a floor drain or installed in a drain pan. HTP
will NOT be held liable for leakage damages.
Figure 2 –Minimum Service Clearances
If you do not provide the minimum clearances shown, it might not be possible to service the storage tank without removing it from the
space.
C. OPTIONAL EQUIPMENT
Below is a list of optional equipment available from HTP:
Aquastat cover with BX and line cord (for GL-50 series only) –Part # GL-KT1
Aquastat cover with BX, line cord, and bronze pump (for GL-50 series only) –Part # GL-KT2
D. WATER CHEMISTRY REQUIREMENTS
Chemical imbalance of the water supply may affect efficiency and cause severe damage to the storage tank and associated equipment.
HTP recommends having water quality professionally analyzed to determine whether it is necessary to install a water softener. It is
important that the water chemistry on both the domestic hot water and central heating sides are checked before installing the storage
tank, as water quality will affect the reliability of the system. Failure of a storage tank 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 storage
tank. Failure of the storage tank due to lime scale build-up on the heating surface, low pH, or other chemical imbalance IS NOT covered
by the warranty.
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

6
LP-181 Rev. 3.25.14
the water precipitate out as the water is heated and cause accelerated lime scale accumulation on a heat transfer surface. This lime
scale build-up may result in premature failure of the storage tank. Operating temperatures above 135oF will further accelerate the build-
up of lime scale and may shorten the service life of the storage tank.
Water that is classified as hard and very hard must be softened to avoid storage tank failure.
CLASSIFICATION
MG/L OR PPM
GRAINS/GAL
Soft
0 –17.1
0 - 1
Slightly Hard
17.1 –60
1 –3.5
Moderately Hard
60 –120
3.5 –7.0
Hard
120 –180
7.0 –10.5
Very Hard
180 and over
10.5 and over
If the hardness of the water exceeds the maximum level of 7 grains per gallon, 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
storage tank or a water heater system 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 storage tank.
The manufacturer of the storage tank 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. Storage tank failure due to total dissolved solids in excess of 2,000 ppm
is a non-warrantable condition. Failure of a storage tank 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 –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 storage tank WILL VOID the warranty. It is also necessary to use both thread tape and pipe dope on all mechanical plumbing
connections.
The use of heat, such as blow torches, near the tank, may cause distortion to the high density polyethylene wrapper. Such damage is
NOT covered by warranty. Exercise caution whenever using heat sources near tank.
When filling the storage tank, open a hot water tap to release air in the tank and piping. Failure to do so could lead to improper storage
tank operation.
B. TANKLESS COIL CONNECTIONS
Refer to dimensional information chart (Figure 1) for correct tankless coil connection size. On the tank, tankless inlet is to be connected
to a bronze or stainless steel circulator with the arrow pointing away from the tank and toward the tankless coil. This pipe will also have
a tee for the cold supply to the tankless coil. (An optional check valve may be installed between the cold supply line and circulator to

7
LP-181 Rev. 3.25.14
prevent short circulating the tankless coil. This may cause poor supply pressure, or noisy operation, depending upon the type of
installation.)
On the tank, tankless outlet, use both thread tape and pipe dope and connect a ¾” NPT brass tee. On the run, install a brass drain
valve. In the branch, install a ¾” (minimum) tube adapter, and connect this to the hot tankless coil outlet on the boiler.
NOTE: See “TYPICAL INSTALLATION”, Figure 3.
C. HOT WATER OUTLET
Use both thread tape and pipe dope to connect an NPT brass tee (refer to dimensional information chart for the correct connection
size).
In the run of the brass tee, install an NPT brass temperature and pressure (T&P) long element for hot water storage tanks, required by
local codes, but not less than a valve certified for meeting the requirements for relief valves for hot water heaters (ANSI Z21.22 and
CAN1-4.4) by a nationally recognized lab that maintains periodic inspection of production of listed equipment. Make sure the valve is
sized to the BTU and storage capacity of the storage tank. The T&P valve must be plumbed down, so discharge will exit at least 6”
above the structural floor and not contact any live electrical parts.
NOTE: See “TYPICAL INSTALLATION” drawing, Figure 3.
Do not thread a cap or plug into the relief valve under any circumstances! Explosion and property damage, serious injury, or death may
result.
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 floor 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 storage tank or in the discharge line. Do not plug or place any
obstruction in the discharge line.
Test the operation of the relief valve after filling 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 heating system “off”
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.
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 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 continued safety.
FAILURE TO RE-INSPECT THIS VALVE AS DIRECTED COULD RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE
BUILDUP WHICH CAN RESULT IN SEVERE PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

8
LP-181 Rev. 3.25.14
D. TYPICAL INSTALLATION
Figure 3 –Typical Storage Tank Installation
E. POTABLE EXPANSION TANK
A thermal expansion tank is required in the system designed for potable water use, to offset the expansion of stored water as the
temperature is elevated.
PART 4 –CONTROL AND WIRING
A. CONTROL
A pre-wired surface mount control is provided on your storage tank. Temperature may be set by removing lower cover screw and lower
cover.
B. WIRING
All wiring is to be done in accordance with all applicable local and state codes. Turn off all power related to the boiler before starting any
wiring procedures.

9
LP-181 Rev. 3.25.14
Figure 4 –Wiring the Control
PART 5 –OPERATING THE STORAGE TANK
Boiler high limit should be set at least 20oF higher than the storage tank temperature setting. Some boilers will require a low
temperature setting to maintain domestic demand.
We recommend a storage tank temperature setting of 120oF. However, a lower temperature setting may be required to comply with
local and state codes for normal operation. You may prefer a setting of either higher or lower water temperature. A mixing valve in
conjunction with a high temperature setting may be used for high demand applications (spas, hot tubs, whirlpools).
If draining of the storage tank is necessary, open the temperature and pressure valve or a hot water tap to prevent vacuum buildup in
the tank and piping.
A temperature limiting or mixing valve is not entirely necessary, but recommended in installations servicing disabled or elderly persons,
or children. Take extreme caution to avoid scalding when temperature limiting or mixing valves are not used.
A water heating system 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 temperature. By setting the thermostat to obtain the increased
water temperature required by these appliances, you may create the
potential for scald injury.
To protect against injury, you should install a mixing valve in the water
system. This valve will reduce point of discharge temperature 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.
Risk of scald injury increases as you increase water 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 1

10
LP-181 Rev. 3.25.14
PART 6 –MAINTENANCE AND TROUBLESHOOTING
Periodic maintenance should be performed by a qualified service technician to assure that all the equipment is operating safely and
efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance. Installer must
also inform the owner that the lack of proper care and maintenance of the water heating system may result in a hazardous condition.
INSPECTION ACTIVITIES
DATE LAST COMPLETED
SYSTEM
1st YEAR
2nd YEAR
3rd YEAR
4th YEAR*
Piping
Check system piping for any sign of leakage; make sure pipes
are properly supported.
Visual
Do a full visual inspection of all system components.
Functional
Test all functions of the system
Temperatures
*Verify safe settings on Mixing Valve
TANK
Check Anode Rod
Verify that anode rod is in good condition.
CAUTION: To avoid scald injury, make sure tank water
temperature is cool before checking anode.
ELECTRICAL
Smoke and CO
detector
*Verify devices are installed and working properly. Change
batteries if necessary.
Circuit Breakers
Check to see that the circuit breaker is clearly labeled.
Exercise circuit breaker.
Connections
Check wire connections. Make sure they are tight.
RELIEF AND DRAIN VALVE
Relief Valve
Lift and release the relief valve on the storage tank. Make
certain that the valve operates properly by allowing several
gallons to flush through the discharge line. Replace if valve is
blocked or does not operate properly.
NOTE: DISCHARGED WATER MAY PRESENT A SCALD
RISK. TAKE CAUTION WHEN OPERATING RELIEF
VALVE.
Drain Valve
Open the drain valve and drain a few quarts of water from the
bottom of the tank to flush any hard water deposits. Replace if
valve is blocked or does not operate properly.
NOTE: DRAINED WATER MAY PRESENT A SCALD RISK.
TAKE CAUTION WHEN OPERATING DRAIN VALVE.
FINAL INSPECTION
Check list
Verify that you have completed entire check list. WARNING:
FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY
OR DEATH
Homeowner
Review what you have done with the homeowner.
INITIAL AND DATE AFTER INSPECTION/SERVICE. CONTINUE INSPECTIONS ON
ANNUALLY BEYOND THE FOURTH YEAR.
Table 2 - *If applicable to system

11
LP-181 Rev. 3.25.14
TROUBLESHOOTING
NO HOT WATER
PROBLEM
POSSIBLE SOLUTION
Zone valve not opening
Open manually to replace.
Circulator not operating
Check or replace
Tank control set too low
Raise tank temperature* (SEE NOTE BELOW)
Boiler control set too low
Raise boiler temperature
Wiring incorrect
Recheck wiring
Tank control failure
Replace control
Zone valve failure
Replace valve
Circulator failure
Replace circulator
Air trap in loop
Purge air
NOT ENOUGH HOT WATER
PROBLEM
POSSIBLE SOLUTION
Zone valve restriction
1” full bore replace zone valve
Circulator arrow reversed
Reverse circulator
Tank temperature too low
Raise tank temperature* (SEE NOTE BELOW)
Boiler temperature too low
Raise boiler temperature
Boiler sized too small
Check sizing chart
Tank sized too small
Check sizing chart
Demand flow rate too high
Install mixing valve, raise tank temperature*
Air trap in loop
Purge to remove air
Install flow regulator
Heat and tank come on together
Recheck wiring or coincidence
Draw tank down and lower thermostat. Recheck.
Not enough space heat
Boiler sized too small. Consult chart.
Slow recovery
Circulator head capacity too low
T & P VALVE DISCHARGES
PROBLEM
POSSIBLE SOLUTION
Tank temperature too high
Lower temperature on tank
Water expands when heated
Install expansion tank
Water pressure too high
Install pressure reducing valve
HOT TUBS, SPAS, MULTIPLE SHOWERS, HIGH DEMAND
PROBLEM
POSSIBLE SOLUTION
Pressure too low
Check line pressure for restriction
Recovery of tank slow
Slow startup boiler. See chart.
Not enough hot water
Boiler sized too small. See chart.
Check flow rate and compare to chart
Demand too great. Check flow rates and compare to chart. Install
mixing valve and/or flow restricting valve and raise tank and boiler
temperature*.
Table 3 - *See scald warning below.
When raising tank temperature, the risk of scald injury increases. To avoid scald injury, use a water tempering or mixing valve and
extreme caution when using hot water. Consult codes for conformance.

12
LP-181 Rev. 3.25.14
HTP 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:
Installation Address:
Date of Installation:
Installer’s Code/Name:
Product Serial Number(s):
Comments:
Installer’s Phone Number:
Signed by Installer:
Signed by Customer:
IMPORTANT:
Customer: Please only sign after the installer has reviewed the installation, safety, proper operation, and maintenance of the
system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please
contact your HTP Sales Representative.
Distributor/Dealer: Please insert contact details.