BTC SST250-65 Installation and Operating manual

Indirect Fired Water Heaters

Installation and Operating Manual

Models: SST150-40

SST250-65

SST300-80

SST450-119

C

®

US

CAUTION:

The heat transfer medium must be water or other nontoxic fl uid having a toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products,

5th edition.

The pressure of the heat transfer medium must be limited to a maximum of 30 PSIG by an approved safety or relief valve .

WARNING:

This manual must only be used by a trained heating installer / service technician. Read all instructions before installing. Perform steps in the order given.

Failure to comply could result in severe personal injury, death, or substantial property damage.

Installation & Operating Manual

2 | Indirect Fired Water Heaters Installation and Operating Manual

Table of Contents

1 General Information 6

2 Pre-installation 7

3 Boiler Side Piping 8

4 Domestic Side (Tank) Piping 13

5 Wiring 17

6 Start-up and Check-out 18

7 Maintenance 19

8 Performance Data 21


Indirect Fired Water Heaters Installation and Operating Manual | 3


Explanation Of Symbols

Warnings

Warnings in this document are identifi ed by a warning triangle printed against a grey background.

Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken.

The following keywords are defi ned and can be used in this document:

 DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

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

 CAUTION indicates a hazardous situation which, if not avoided, could result in minor to moderate injury.

 NOTICE is used to address practices not related to personal injury.

Important information

Important information in cases where there is no risk of personal injury or material losses is identifi ed by the symbol shown on the left. It is bordered by horizontal lines above and below the text.

Please Read Before Proceeding

DANGER: Installer – Read all instructions before installing.

Perform steps in the order given. Have this indirect water heater serviced/inspected by a qualifi ed service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

NOTICE:

When calling or writing about the appliance

– Please have the indirect water heater model and serial number from the indirect water heater rating plate.

– Consider piping and installation when determining appliance location.

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

– Factory warranty does not apply to appliances improperly installed or improperly operated.

DANGER:

If the information in this manual is not followed exactly, a fi re or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or fl ammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

– Do not try to light any appliance.

– Do not touch any electric switch; do not use any phone in your home/building.

– Evacuate the home/building immediately.

– Immediately call your gas supplier. Follow the gas supplier’s instructions.

– If you cannot reach your gas supplier, call the fi re department.

– Installation and service must be performed by a qualifi ed installer, service agency, or the gas supplier.



DANGER: HOT WATER CAN SCALD!

Water heated to temperatures for clothes washing, dish washing, and other sanitizing needs can scald and cause permanent injury.

Children, elderly, and infi rm or physically handicapped persons are more likely to be permanently injured by hot water. Never leave them unattended in a bathtub or shower. Never allow small children to use a hot water tap or draw their own bath.

If anyone using hot water in the building fi ts the above description, or if state laws or local codes require certain water temperatures at hot water taps, you must take special precautions:

– Use lowest possible temperature setting.

– Install some type of tempering device, such as an automatic mixing valve, at hot water tap or water heater. Automatic mixing valve must be selected and installed according to valve manufacturer’s recommendations and instructions.

Water passing out of drain valves may be extremely hot. To avoid injury:

– Make sure all connections are tight.

– Direct water fl ow away from any person

Protection Must Be Taken Against Excessive

Temperature and Pressure! Installation of a

Temperature & Pressure (T&P) relief valve is required.

DANGER:

Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.

When Servicing the Indirect Water Heater -

To avoid severe burns, allow the appliance to cool before performing maintenance.

Indirect water heater operation –

Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator.

Instead, shut off the gas supply at a location external to the appliance.

Do not use this appliance if any part has been under water. The possible damage to a fl ooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

The following chart 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.

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120° F More than 5 minutes

125° F 1 ½ to 2 minutes

130° F

135° F

140° F

About 30 seconds

About 10 seconds

Less than 5 seconds

145° F

150° F

155° F

Less than 3 seconds

About 1 ½ seconds

About 1 second



1 General Information

The SST series indirect water heater (FIG. 1-1) is designed to generate domestic hot water in conjunction with a hot water boiler using forced boiler water circulation. This indirect water heater consists of a 316L Stainless Steel tank in which a smooth 304L stainless steel coil is located

(Table 1A). Boiler water is pumped through the coil and heats the water in the tank. This tank is not intended for use in pool heating applications or for heating any fl uid other than water. It is also not intended for use in gravity hot water heating systems.

Operating Restrictions:

• Maximum domestic hot water temperature is 194°F.

• Maximum boiler water temperature is 210°F.

• Maximum working pressure for the vessel tank is 150 psig.

Component Materials

Table 1A

Component

Tank

Coil

Insulation

Jacket

Material

316L Steel Stainless Steel

304L Stainless Steel

Polyurethane

Polypropylene/ABS

Single-Wall Heat Exchanger

National Standard Plumbing Code

Single-wall heat exchangers in water heaters comply with the National Standard Plumbing Code provided that:

• boiler water (including additives) is practically non-toxic, having a toxicity rating or class of 1, as listed in Clinical

Toxicology of Commercial Products, and

• boiler water pressure is limited to a maximum of 30 psig by approved relief valve.

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.

2. The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the potable water system.

3. The equipment is permanently labeled to indicate that only additives recognized as safe by the FDA shall be used in the heat transfer medium.

Other heat exchanger designs may be permitted where approved by local code.

Figure 1-1

6 |

“E”

“D”

“C”

“B”

“A”

“F”

PART NO.

SST150-40

SST250-65

SST300-80

SST450-119

NOTES:

1. 1” NPT ON SST150-40.

“A”

(in.)

3

3 1/4

3 1/4

3 1/4

22.5°

45°

1-1/2” NPT (SEE NOTE 1) 2

“B”

(in.)

8 1/4

9 1/4

9 1/4

9 1/4

“C”

(in.)

25 1/4

28

28

31 3/4

“D”

(in.)

48 1/2

52 1/2

61 3/4

60 1/4

“E”

(in.)

56

60

70

69

“F”

(in.)

WEIGHT

FULL OF WATER

(lbs.)

20

24

24

28

515

820

921

1268

2. HOT WATER OUTLET

3. BOILER WATER IN

3/4” NPT 1

1” NPT 3

AQUASTAT/SENSOR WELL

1” NPT 4

1-1/2” NPT (SEE NOTE 1) 5

SST150 - SST450

Indirect Fired Water Heaters Installation and Operating Manual


2 Pre-installation

1. The installation must conform to the instructions in this manual and all applicable local, state, provincial, and national codes, laws, regulations, and ordinances.

Installations in Canada must conform to B149.2

Installation Code.

2. Be certain the domestic water supply to the tank has physical and chemical characteristics that fall within the limits shown in Table 2A. Where questions exist as to the composition of the water on the job, a qualifi ed water treatment expert should be consulted.

CAUTION:

Water with characteristics outside the limits shown in Table 2A may severely shorten the life of the tank due to corrosion. Damage to tanks in such cases is not covered under warranty.

3. Read and understand all installation requirements in this manual.

Water Chemistry Requirements

Table 2A

Water used in the tank must have characteristics falling within the following limits:

Characteristic

Ph

Chloride (PPM)

Min.

6.0

--

Max.

8.0

80

Locating the Tank

1. Choose a location for your water heater centralized to the piping system. You must also locate the SST water heater 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 certifi ed as an indoor appliance, and must also be kept vertical on a level surface.

2. Keep distance between boiler and water heater to a minimum to: a. reduce piping heat loss b. provide minimal friction loss

3. Figure 1-1 on page 6 shows the weights of all the tanks fi lled with water. Make sure that the location chosen for the tank is capable of supporting it.

CAUTION:

This appliance must be placed where leakage from the temperature and pressure

(T&P) 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 fl oors of the building. A water heater should always be located in an area with a fl oor drain or installed in a drain pan suitable for water heaters. The manufacturer shall not be held liable for any such water damage. Damage caused by the failure to properly install a drain pan or in an area with a drain is not the responsibility of the manufacturer or Bosch

Thermotechnology Corp. (BTC).

4. The tank may be located some distance from the boiler provided the pump is designed to provide the fl ow called for in Table 3B - Pressure Drop Values, through the coil. Also, the further the tank is from the boiler, the longer the response of the boiler will be to a call from the tank zone. Insulate piping between the boiler and the tank.

WARNING:

Failure to properly support the tank could result in property damage or personal injury.

Recommended Clearances

The installation location must provide adequate clearances for servicing and proper operation of the water heater. A

12 inch vertical clearance is recommended from the top of the water heater. A zero clearance is allowed for the sides of the water heater. However, boiler and servicing clearances must be fi gured when locating the water heater.



3 Boiler Side Piping

.

Figures 3-1 thru 3-4 show typical boiler side piping for several common situations. Regardless of which system is used it is imperative that the fl ow rates called for in Table

3B are developed through the coil. This requires properly sized piping and a properly sized pump. The system shown in FIG’s 3-1 thru 3-4 are described below:

DHW Prioritization

This piping system is designed to provide direct hot water priority over the other zones in the heating system. When there is a Domestic Hot Water (DHW) call for heat, the controller will shut off the boiler circulator and activate the domestic hot water circulator. Once the DHW demand is satisfi ed, the boiler circulator will be readjusted as demand requires. The circulator must be large enough to move the boiler water through the coils. The recommended piping for a DHW priority system is depicted in FIG. 3-1 and 3-2 using a GB142 wall hung boiler.

Zone with Circulator to Aquastat

This system is like the circulator zone system on a straight heat job except that one of the zones goes to the tank instead of radiation. As on any circulator zone system check valves should be installed in each zone to prevent unwanted circulation through zones which are not calling for heat. Figure 3-3 illustrates typical circulator zone piping with a fl oor standing G115WS, G125BE, GB125BE, or

G215 boiler.

Multiple Tank Connections (Boiler Side)

Multiple tank installations must be done in the “reversereturn” manner. The reason for this is to create the same pressure drop (and therefore, the same fl ow) through the coil of each tank. The boiler manifold piping must be sized so that each coil has the fl ow rate called for in Table 3B.

Because the pressure drop through tank coils varies from size to size, it is hard to predict the fl ow rate that will be developed through each coil when two tanks of different sizes are placed in the same manifold. For this reason it is best not to mix tanks of different sizes in the same zone if their recovery is critical. A sample system is shown in FIG.

3-4.

Pressure Drop Chart

12

10

8

6

4

2

Table 3A

SST450-119

SST250-65/

SST300-80

SST150-40

0

0 5 16 20 8

Flow Rate

12

Pressure Drop Values Table 3B

Model

SST250-65

SST300-80

SST450-119

Water

Inlet

(IN)

SST150-40 1

1.5

1.5

1.5

Water

Outlet

(IN)

1

1.5

1.5

1.5

Coil

Connection

(IN)

1

1

1

1

Coil

Length

(FT)

30.8

41.5

41.5

67.3

Surface area

(SQ-FT)

10.0

13.5

13.5

22.0

5

GPM

0.41

0.61

0.61

0.73

Pressure Drop (FT/HD)

8

GPM

1.04

1.57

1.57

1.87

12

GPM

2.34

3.53

3.53

4.22

16

GPM

20

GPM

4.16

6.49

6.27

9.80

6.27

9.80

7.50

11.71



AIR

SEPARATOR

SYSTEM SUPPLY

SENSOR

TO

SYSTEM

BALL VALVE

(TYPICAL)

AIR

SEPARATOR

SYSTEM

PUMP

EXPANSION

TANK

GB 142

BOILER

DHW

TANK

PUMP

DRAIN

POINT

Y-STRAINER

(RECOMMENDED)

FROM

SYSTEM

ANTI-SCALD

MIXING VALVE

HOT

WATER

OUT

COLD

WATER

IN

PRESSURE RELIEF

VALVE

TANK SENSOR

CHECK VALVE

SST series tank

RECIRCULATION

PUMP

DRAIN

( FIELD SUPPLY )

Figure 3-1 GB142 Boiler Low Loss Header piping and DHW priority

NOTICE:

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.



PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

PRESSURE

GAUGE

MAKE UP WATER

AIR SEPARATOR

ZONE PUMPS

(TYPICAL)

EXPANSION

TANK

PUMP

GB 142

BOILER

CHECK VALVE

HOT

WATER

OUT

ANTI-SCALD

MIXING VALVE

COLD

WATER

IN

PRESSURE RELIEF VALVE

BALL VALVE

TANK SENSOR

DRAIN

POINT

Y-STRAINER

(RECOMMENDED)

SST series tank

Figure 3-2 Piping diagram zoned with circulators and DHW priority

NOTICE:


RECIRCULATION

PUMP

CHECK VALVE

DRAIN

( FIELD SUPPLY )

1 0 | Indirect Fired Water Heaters Installation and Operating Manual


PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

PRESSURE

GAUGE

MAKE UP WATER

AIR SEPARATOR

Y-STRAINER

(RECOMMENDED)

EXPANSION

TANK

BALL

VALVE

FLOW

CHECK

VALVE

DHW

TANK

PUMP

BALL

VALVE

G115WS/G125BE/GB125BE

DRAIN

POINT

ZONE PUMPS

(TYPICAL)

HOT

WATER

OUT

ANTI-SCALD

MIXING VALVE

COLD

WATER

IN

PRESSURE RELIEF VALVE

TANK SENSOR

SST series tank

Figure 3-3 Piping diagram of fl oor standing boiler and DHW priority

RECIRCULATION

PUMP

CHECK VALVE

DRAIN

( FIELD SUPPLY )

NOTICE:




AIR

SEPARATOR

DHW

TANK

PUMP

GB 142

BOILER

TO

SYSTEM

AIR

SEPARATOR

SYSTEM SUPPLY

SENSOR

BALL VALVE

(TYPICAL)

SYSTEM

PUMP

EXPANSION

TANK

DRAIN

POINT

Y-STRAINER

(RECOMMENDED)

FROM

SYSTEM

HOT

WATER

OUT

ANTI-SCALD

MIXING VALVE

COLD

WATER

IN

RECIRCULATION

PUMP

CHECK VALVE

PRESSURE

RELIEF VALVE

(TYPICAL)

TANK SENSOR

(TYPICAL)

SST series tank SST series tank

DRAIN

( FIELD SUPPLY )

Figure 3-4 Multiple tank connections in reverse return

NOTICE:




4 Domestic Side (Tank) Piping

Basic Domestic Piping

Figure 4-2 shows typical domestic water piping for a tank.

The function of the components shown are as follows: a. Shut-off valves (recommended) - Used to isolate the tank for servicing.

b. Backfl ow Preventer (required by some codes) -

Used to prevent water from backing out of the tank in the event that inlet water pressure drops.

c. Expansion Tank (required when a backfl ow preventer is used) - This expansion tank absorbs the increased volume caused by heating water.

Use an expansion tank designed for use on domestic water systems. Refer to the expansion tank manufacturer’s literature for the proper size expansion tank to use.

NOTICE:

If an expansion tank is used, do not put any valves between the expansion tank and tank inlet.

Domestic Water Piping for Distant Fixtures

In some cases the furthest fi xture may be quite distant from the tank. Such an installation would result in an unacceptable delay before hot water reaches these distant fi xtures. Even if all the fi xtures are relatively close to the tank, the building owner may want hot water at all fi xtures as soon as they are opened.

A solution to this problem is that a pipe runs from the furthest fi xture on each branch back to the return of the tank (reference FIG. 4-2). A small DHW recirculation pump is mounted in this line and is wired so as to run continuously. A check valve in this line permits fl ow towards the tank inlet only.

When no fi xtures are drawing water, the DHW recirculation pump moves hot water from the tank to the end of the branch just below the last fi xture, then back to the inlet of the tank via the return pipe. When a fi xture is opened, hot water is already out in the branch very close to the fi xture and hot water appears at it almost immediately. The check valve prevents cold water in the tank’s inlet pipe from passing around the tank and heading directly to the fi xture.

Because hot water is always circulating in the hot water branch the entire branch should be insulated to prevent excessive heat loss.

d. Unions (optional) - Used to disconnect the tank in the unlikely event that this is necessary.

e. Drain (required) - Used to drain the tank for inspection or servicing.

Multiple Tank Domestic Water Piping

The two pipe reverse return piping uses more pipe than the two pipe direct return piping, but the fl ow is more balanced and even in the two pipe reverse return piping layout (see FIG. 3-4).

Each tank must have its own T&P valve. It is recommended that each tank be equipped with its own isolation valves, unions, and drains so that one tank may be removed from the system. If local codes require a backfl ow preventer, check with the appropriate authority to fi nd out whether one backfl ow preventer may be used for tanks or each tank must be equipped with its own backfl ow preventer. If each tank must have its own backfl ow preventer, each tank must also have its own expansion tank. If a common backfl ow preventer is permitted, an expansion tank must be sized to accommodate the expansion volume of all tanks.



Anti-scald Valves (Mixing Valves)

Anti-scald valves used with water heaters are also called tempering valves or mixing valves. An anti-scald valve mixes cold water in with the outgoing hot water to assure that hot water reaching a building fi xture is at a temperature low enough to be safe.

Usually, the maximum temperature of the outlet water will stay near the setting of the tank control. In some cases, however, hot water usage patterns can cause the outlet water temperature to rise signifi cantly above the control setting.

The temperature of water going to the fi xtures may be more carefully controlled through the use of a thermostatic mixing valve. This device blends a controlled amount of cold water with the hot water leaving the tank so that water at a more constant temperature exits the mixing valve. Anti-scald mixing valve piping is illustrated in

FIG.’s 3-1 thru 3-4.

WARNING:

An anti-scald mixing valve does not eliminate the risk of scalding.

– Set the tank thermostat as low as practical.

– Feel water before bathing or showering.

– If anti-scald or anti-chill protection is required, use devices specifi cally designed for such service. Install these devices in accordance with their manufacturer’s instructions.

Temperature & Pressure (T&P) Relief Valve

WARNING:

For protection against excessive temperatures and pressure, install temperature and pressure protective equipment required by local codes, but not less than a combination temperature and pressure (T&P) relief valve certifi ed by a nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials as meeting the requirements for Relief Valves and Automatic

Gas Shutoff Devices for Hot Water Supply

Systems, ANSI Z21.22 and the Standard CAN1-

4.4, Temperature, Pressure, Temperature and

Pressure Relief Valves and Vacuum Relief Valves.

The combination temperature and pressure relief valve shall be marked with a maximum set pressure not to exceed the maximum working pressure of the water heater. The combination temperature and pressure relief valve shall also have an hourly rated temperature steam BTU discharge capacity not less than shown in Table

4A.

Install the combination temperature and pressure relief valve into the opening provided and marked for this purpose on the water heater. Failure to properly install the correct temperature and pressure (T&P) relief valve can result in a discharge of hot water that can cause severe personal injury or substantial property damage.

Install Drain Valve

Drain valve and fi ttings are supplied by others.

Standard Installation

• Install a tee connection at the domestic cold water inlet

(FIG. 4-1).

NOTICE:

Verify that the combination temperature and pressure (T&P) relief valve complies with local codes. If the combination temperature and pressure relief valve does not comply with local codes, replace it with one that does. Follow the installation instructions in this section.

Figure 4-1 Drain valve installed

DRAIN

VALVE



Do not place a valve between the combination temperature and pressure relief valve and the tank.

Standard Installation

• Install the T&P relief valve in the connection marked

“Relief Valve”.

Determine T&P relief valve size by the following specifi cations, unless they confl ict with local codes:

- SST150-40 - 3/4” NPT with a minimum AGA Rating of

105,000 Btu/hr.

- SST250-65/300-80/450-119 - 3/4” NPT with a minimum AGA Rating of 200,000 Btu/hr.

T&P Relief Valve Discharge Piping

T&P relief valve discharge piping must be:

- made of material serviceable for a temperature of

250°F or greater.

- directed so that hot water fl ows away from all persons.

- directed to a suitable place for disposal.

- installed so as to allow complete draining of the T&P relief valve and discharge line.

- terminated within 6” of the fl oor.

T&P relief valve discharge piping must not be:

- excessively long. Using more than two (2) elbows or 15 feet of piping can reduce discharge capacity.

- directly connected to a drain. Refer to local codes.

- subject to freezing.

NOTICE:

The SST series water heaters will absorb/ store less than 200,000 Btu/hr when domestic water outlet temperature is 210°F and boiler water supply temperature is

240°F. Listed outputs are based on ASME

Section VIII Interpretation VIII-1-86-136.

Check with local codes for applicability.

DANGER:

Do not install any valve between the temperature and pressure (T&P) relief valve and the tank connection or on the T&P relief valve discharge piping. Improper placement and piping of T&P relief valve may result in a discharge of hot water that can cause severe personal injury, death or substantial property damage.

Minimum Relief Valve (AGA Rating) Table 4A

Model

SST150-40

SST250-65

SST300-80

SST450-119

BTU/hr

105,000

200,000

200,000

200,000

WARNING:

The temperature and pressure (T&P) relief valve is not intended for constant duty, such as relief of pressure due to repeated normal system expansion. Correct this condition by installing a properly sized expansion tank in a domestic water system.

Refer to the expansion tank manufacturer’s installation instructions for proper sizing.

Be advised, the hot discharge water from the temperature and pressure (T&P) relief valve, can cause severe personal injury, or substantial property damage.

WARNING:

Failure to install and maintain a new, listed

¾" X ¾" temperature and pressure (T&P) relief valve will release the manufacturer from any claim which might result from excessive temperature and pressures or discharge of hot water.



FROM BOILER

TO BOILER

ANTI-SCALD

MIXING VALVE

SHOCK ARRESTOR

UNION

(TYPICAL)

SHUTOFF VALVE

SHUTOFF

VALVE

SHUTOFF

VALVE

SHUTOFF

VALVE

BACKFLOW

PREVENTER

EXPANSION

TANK

TANK SENSOR / AQUASTAT

SST SERIES TANK

CHECK VALVE

DRAIN

( FIELD SUPPLY)

RECIRCULATION

PUMP

Figure 4-2 Recommended domestic water piping

NOTICE:




5 Wiring

Wiring using boiler sensor:

1. For wiring using boiler sensor, see boiler installation manual.

Indirect Water Heater Controlled Using Aquastat and Zone Circulator / Valve:

1. Install Aquastat to tank. Aquastat control

(Honeywell L4006 or equivalent) can be ordered from your local distributor.

2. Connect Aquastat to the zone controller for the Indirect

Water Heater Zone.

3. Adjust Aquastat to the desired temperature.

TEMPERATURE

ADJUSTMENT

WIRE

CONNECTIONS

Honeywell

L4006 or equivalent

ZONE CONTROL BOX

OR

ZONE VALVE

OR

ZONE CIRCULATOR

INDIRECT TANK

Figure 5-1 Wiring for zone control

Indirect Fired Water Heaters Installation and Operating Manual

AQUASTAT

CONTROL

| 17


6 Start-up and Check-out

1. Make sure the system is free of leaks and that air is purged from the system.

CAUTION:

Fix any leaks found before proceeding further.

Leakage from the boiler piping can result in severe damage to the boiler.

2. Many soldering fl uxes contain Zinc Chloride which can cause severe corrosion damage to stainless steel. After completing all domestic water connections, fl ush the indirect water heater thoroughly before leaving the installation. This is particularly important if the indirect water heater will be unused for an extended period of time after installation. Flush the indirect water heater by drawing at least three times its volume from the tank.

3. Make sure that all electrical connections are made correctly and that no exposed high voltage wiring is present.

4. Make sure that each zone valve or circulator operates when, and only when, its thermostat calls for heat. Let each zone operate long enough to purge any remaining air from the system.

5. Set the indirect water heater to the desired temperature. Because hot water presents a scald hazard, it is best to set the thermostat at 120°F or lower and raise it only if necessary to provide adequate hot water.

6. Re-enable the burner and allow the boiler to operate.

Make sure that the boiler shuts down when the indirect water heater is satisfi ed.

7. After installation, installer to review with homeowner their maintenance responsibilities and their frequencies,

See Sec. 7 Maintenance.



7 Maintenance

The SST series indirect water heater system requires annual inspection and maintenance to ensure a reliable supply of hot water:

• Make sure that the rest of the boiler and domestic water piping is free of leaks.

• The indirect water heater depends upon the boiler for a source of heat and is therefore only as reliable as the boiler.

• Make sure that the boiler is maintained in accordance with the boiler manufacturer’s instructions.

• If a water treatment system is required to keep the water chemistry within the parameters shown in Table 2A (see

Section 2 - Pre-Installation), make sure that this system is properly maintained.

Maintenance Schedule

Annual service by a qualifi ed service technician includes the following:

1. Any procedure required by local codes.

2. Verify system pressure. Air venting procedure may require adding water to bring boiler system up to pressure, typically 12 psig.

3. Manually operate T&P relief valve at least once a year.

This will release some hot water.

WARNING:

Before operating a temperature and pressure

(T&P) relief valve, make sure no one is in front of or around the T&P relief valve discharge piping. Hot discharge water can cause severe personal injury or substantial property damage.

4. Move operating lever to open position for a few seconds and then move it back, allowing it to snap closed. After the T&P relief valve is operated, if it continues to release water, close the cold water inlet to the water heater immediately. Follow the draining instructions, and replace the T&P relief valve. If the

T&P relief valve weeps periodically, it may be due to thermal expansion. Do not plug the T&P relief valve or discharge piping.

DANGER:

Plugging the temperature and pressure

(T&P) relief valve or discharge piping can cause excessive pressure in the water heater, resulting in severe personal injury, death, or substantial property damage.

Homeowner monthly maintenance to include:

1. Visually check valves, pipes, and fi ttings for leaks. Call a qualifi ed service technician to repair leaks.

To Fill the Water Heater

1. Close the water heater drain valve by turning the knob clockwise.

2. Open the cold water supply shutoff valve. Open several hot water faucets to allow air to escape from the system.

3. When a steady stream of water fl ows from the faucets, the water heater is fi lled. Close the faucets and check for water leaks at the water heater drain valve, combination temperature and pressure relief valve and the hot and cold water connections.

DANGER:

Water from opened drain valves, unions and other connections may be extremely hot.

To avoid severe personal injury, death, or substantial property damage:

– Tighten all drain hose connections.

– Direct hot water away from all persons.

To Drain the Water Heater

Should it become necessary to completely drain the water heater, be sure to follow the steps below:

1. Disconnect the power supply to the heat source.

Consult the plumbing professional or electric company in your area for service.

2. Close the cold water supply shutoff valve.

3. Open the drain valve on the water heater.

4. Open a hot water faucet to allow air to enter the system.

Drain the water heater if it will be shut off and exposed to freezing temperatures. Freezing water will expand and damage the water heater.

• If boiler water contains suffi cient antifreeze, then only the domestic water needs to be drained.

• If boiler water does not contain suffi cient antifreeze, the boiler water and the domestic water must be drained.



If antifreeze is used in the boiler water, check concentration. Boiler water (including additives) must be practically non-toxic, having a toxicity rating or class of 1, as listed in the “Clinical Toxicology of Commercial

Products”. A maximum 50/50 mixture of inhibited propylene glycol is recommended. Follow the antifreeze manufacturer’s instructions.

DANGER:

Do not use automotive, ethylene glycol or petroleum-based antifreeze. These types of antifreezes are toxic and could cause severe personal injury or death if leakage into the domestic hot water supply occurs. Do not use any undiluted antifreeze. This can cause severe personal injury, death, or substantial property damage.



8 Performance Data

Indirect Water Heater Table 8A

Model

SST150-40

SST250-65

SST300-80

SST450-119

Potable

Water

Volume

Gal.

40.0

67.0

81.5

113.4

Heat

Source

Water

Volume

Gal.

1.6

1.9

2.1

3.2

Standby

Heat Loss

F/hr

Continuous

Draw

Rating

Gal/hr

0.9

0.7

0.6

0.5

181

263

266

322

• These ratings were obtained with a heat source output and heat source fl ow rate as listed in the chart using the parameters of the Domestic Cold Water Inlet at 58°F,

Domestic Temperature Rise of 77°F, and a Boiler

Temperature Output of 180°F. Other results will be obtained under different conditions.

208

327

347

431

First

Hour

Rating

Gal/hr

Minimum

Heat Output

Rate from

Heat Source

Btu/hr

115,000

154,000

171,000

199,000

Minimum

Heat

Source

Flow Rate

GPM

14.0

Tank Heat

Source

Friction

Loss Feet

W.C

4.5

14.0

14.0

14.0

5.7

5.7

6.5



How to Properly Size Your Indirect Water Heater

Use the First Hour Rating (FHR) to properly size your

Indirect Water Heater. The First Hour Rating is the amount of hot water in gallons the heater can supply per hour

(starting with a tank full of hot water), depending on tank capacity, source of heat, and the size of the burner.

Estimate your peak hour demand as follows:

• Determine what time of day (morning, noon, evening) you use the most hot water in your home. Keep in mind the number of people living in your home.

• Use the worksheet below to estimate your maximum usage of hot water during this one hour of the day -- this is your peak hour demand. Note: The worksheet does not estimate total daily hot water usage.

The worksheet example shows a total peak hour demand of 165 gallons; therefore, this household would need a water heater with a First Hour Rating of no less than 165 gallons.

Fixture Count Guide

To quickly estimate the minimum gallons of hot water required based on a family size number of baths and hot water appliances the First Hour Rating of the STS tank must be equal to or exceed the total fi rst hour requirements.

Peak Hour Demand Worksheet

Description

40 Gallons for the fi rst 2 people

10 Gallons for each additional person

20 Gallons for each bath after the fi rst

(consecutive bath)

10 Gallons if dishwasher is used

Fill in the Blank

___________________________

___________________________

___________________________

20 Gallons if clothes washer is used

TOTAL

Heavy Usage Buffer

Use if family members take longer than average showers, etc.

___________________________

___________________________

___________________________ x 1.5

First Hour Rating

Proceed to pages 23 & 24 of this manual to locate your

Indirect Water Heater and Boiler in the sizing charts. Using the First Hour Rating calculated in this worksheet, locate your Indirect Water Heater and Boiler along with your First

Hour Rating. This will also determine the fl ow needed between the Indirect Water Heater and Boiler.

___________________________

Gals.

Gals.

Gals.

Gals.

Gals.

Gals.

Gals.

10

20

110 x 1.5

Example

40

20

20

Gals.

Gals.

Gals.

165

Gals.

Gals.

Gals.

Gals.



First Hour Rating - 180°F Boiler Loop Water (Universal Sizing - 45,000 - 295,000 Btu/hr) Table 8B

Model

Circulator Flow

(GPM)

5 8

SST150-40

12 16 20 5 8

SST250-65

12 16 20

Domestic Outlet 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140

45,000 122 97 122 97 153 128 153 128

60,000 150 118 150 118 183 149 183 149

75,000

95,000

115,000

179 138 179 138

217 165 217 165 217 165

217 165 252 189 252 189 252 189

213 170 213 170

252 197 252 197 252 197

291 226 291 226 291 226 291 226

140,000

165,000

195,000

225,000

260,000

295,000

Max BTU Input 92,998

252 189 267 200 282 211 286 208 305 235 319 245 338 259 338 259 338 259

112,972

267 200 282 211 286 213 305 235 319 245 356 271 386 293 388 294

123,331 129,574 132,764 118,488

319 245 356 271 386 293 388 294

129,139

356 271 386 293 388 294

146,864 163,768

388 294

167,924



First Hour Rating - 180°F Boiler Loop Water (Universal Sizing - 45,000 - 295,000 Btu/hr) Table 8C

Model

Circulator Flow

(GPM)

5 8

SST300-80

12 16 20 5 8

SST450-119

12 16 20

Domestic Outlet 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140 115 140

45,000

60,000

75,000

163 138 163 138

193 159 193 159

222 180 222 180

197 172 197 172

226 193 226 193

255 213 255 213

95,000

115,000

140,000

261 207 261 207 261 207

300 235 300 235 300 235 300 235

294 241 294 241 294 241

333 268 333 268 333 268 333 268

304 238 347 268 347 268 347 268 347 268 384 302 382 302 382 302 382 302 382 302

165,000

195,000

225,000

260,000

295,000

Max BTU Input

304 238 349 270 374 288 395 302 395 302 387 306 429 337 429 337 429 337 429 337

349 270 374 288 409 312 424 323

374 288 409 312 424 323

424 323

483 375 485 376 485 376 485 376

501 388 548 421 541 416

573 438 596 454

596 454

115,860 139,106 154,002 171,229 181,544 141,419 190,161 204,795 237,649 253,504


Notes:







United States and Canada

Bosch Thermotechnology Corp.

50 Wentworth Avenue

Londonderry, NH 03053

Tel: 603-552-1100

Fax: 603-965-7581 www.bosch-climate.us

BTC 471003301 D / 08.2014

SST-I-O Rev D

BTC SST250-65 Installation and Operating manual

Indirect Fired Water Heaters

Installation and Operating Manual

Table of Contents

1 General Information 6

2 Pre-installation 7

3 Boiler Side Piping 8

4 Domestic Side (Tank) Piping 13

5 Wiring 17

6 Start-up and Check-out 18

7 Maintenance 19

8 Performance Data 21

Explanation Of Symbols

Warnings

Important information

Please Read Before Proceeding

When Servicing the Indirect Water Heater -

Indirect water heater operation –

1 General Information

Operating Restrictions:

Component Materials

Single-Wall Heat Exchanger

2 Pre-installation

Water Chemistry Requirements

Locating the Tank

Recommended Clearances

3 Boiler Side Piping

DHW Prioritization

Zone with Circulator to Aquastat

Multiple Tank Connections (Boiler Side)

Flow Rate

Figure 3-4 Multiple tank connections in reverse return

4 Domestic Side (Tank) Piping

Basic Domestic Piping

Domestic Water Piping for Distant Fixtures

Multiple Tank Domestic Water Piping

Anti-scald Valves (Mixing Valves)

Temperature & Pressure (T&P) Relief Valve

Install Drain Valve

5 Wiring

Wiring using boiler sensor:

Indirect Water Heater Controlled Using Aquastat and Zone Circulator / Valve:

6 Start-up and Check-out

7 Maintenance

Maintenance Schedule

8 Performance Data

How to Properly Size Your Indirect Water Heater

TOTAL

Notes:

United States and Canada

Bosch Thermotechnology Corp.

50 Wentworth Avenue

Londonderry, NH 03053

Tel: 603-552-1100

Fax: 603-965-7581 www.bosch-climate.us

BTC 471003301 D / 08.2014

SST-I-O Rev D

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