H E A T T R A N S F E R P R O D U C T S

I N D I R E C T F I R E D WAT E R H E AT E R S

RESIDENTIAL COMMERCIAL

Heat Transfer Products, Inc., reserves the right to make product changes or updates without notice.

Heat Transfer Products will not be held liable for typographical errors in literature. For questions, please consult the factory.

2

A. INSTALLATION SEQUENCE

Follow the installation instructions provided in this manual in the order shown. The order of these instructions has been set in order to provide the installer with a logical sequence of steps that will minimize potential interferences and maximize safety during heater installation.

B. SPECIAL ATTENTION BOXES

Throughout this manual you will see these special attention boxes to the right of this page which are intended to supplement the instructions and make special notice of potential hazards. These categories are as defined by the ANSI Z535.A Standard.

USING THIS MANUAL

DANGER

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

WARNING

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

CAUTION

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

CAUTION

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

CUTAWAY ILLUSTRATION

INTRODUCING THE NEW SUPER-STOR ULTRA

Stainless steel nipple welded to tank

Hot water outlet, T & P

Domestic water connections

(see chart for sizes)

2" (5.08 cm) Polyurethane foam insulation on outside; less than .5˚F (.28˚C) per hour heat loss (R17)

316L stainless steel

Factory installed enclosed thermostat well

Plastic jacket

Stainless steel nipple welded to tank

Cold inlet & drain

Boiler supply 1"

Cupronickel coil assembly

Boiler return 1"

New mechanical heat exchanger connection

SPECIFICATIONS AND PERFORMANCE RATINGS

ULTRA RESIDENTIAL SERIES

M O D E L

S S U 2 0

S S U 3 0

S S U 3 0 L B

S S U 4 5

S S U 6 0

S S U 8 0

D I

H

2

M E N S I

T

7

.

"

O N S

D I A .

1 9 ¼ "

C A P A C I T Y

H E A T E X C H .

S U R F A C E

2 0 1 5 S Q .

F T .

R E C O M M .

F L O W R A T E

8

D

P R E S S U R E

R O P ( F E E T )

1 8 0 °

F I R S T

B O I L E R

H O U R

W A T E R

R A T I N G S *

1 4 0 ° F 1 1 5 ° F

2 0 0 °

F I R S T

B O I L E R

H O U R

W A T E R

R A T I N G S *

1 4 0 ° F 1 1 5 ° F

6 .

0 1 2 1 g a l 1 6 8 g a l 1 3 6 g a l 1 8 5 g a l

3

2

9

8

½

½

"

"

1

2

9

3

¼

¼

"

"

3

3

0

0

1

1

5

5

S Q

S Q .

.

F

F

T

T

.

.

8

8

6

6 .

.

0

0

1

1

5

6

4

9 g g a a l l

2

2

1

3

2

4 g g a a l l

1

1

7

8

2

9 g g a a l l

2

2

3

5

4

7 g g a a l l

5 2 ½ "

5 2 ½ "

7 2 "

1 9 ¼ "

2 3 ¼ "

2 3 ¼ "

4 5

6 0

8 0

2 0 S Q .

F T .

2 0 S Q .

F T .

3 4 S Q .

F T .

1 0

1 0

1 2

7 .

9

7 .

9

9 .

1

2 1 2 g a l

2 6 6 g a l

3 3 0 g a l

2 9 2 g a l

3 7 0 g a l

4 4 0 g a l

2 3 7 g a l

2 9 8 g a l

3 7 0 g a l

S S U 1 1 9 7 3 ½ " 2 7 " 1 1 9 3 4 S Q .

F T .

1 4 1 1 .

3 4 2 3 g a l 5 6 4 g a l

*DOE TEST METHOD BASED ON 90°F. TEMPERATURE RISE, 50°/140° W/ BOILER WATER AT 180°F

4 7 4 g a l

3

4

2

0

2

5 g g a a

5 0 3 g a l

6 4 5 g a l l l

T A N K S I Z E

S S U 2 0

S S U 3 0

S S U 3 0 L B

S S U 4 5

S S U 6 0

S S U 8 0

S S U 1 1 9

F L O O R T O

B O I L

S U P P

E R

L Y

9 "

F L O O R T O

B O I L E R

R E T U R N

4 ½ "

F L O O R T O

D O M E S

O U T

T I C

D O M E S T I C

C O N N E C T I O N S

T E S T

P R E S S U R E

W O R K I N G

P R E S S U R E

2 2 " ¾ N P T M A L E 3 0 0 P S I 1 5 0 P S I

S H I P P I N G

W E I G H T

1 8 0 B O I L E R

B T U / S I Z E

2 0 0 B O I L E R

B T U / S I Z E

6 0 L B S .

8 4 , 0 0 0 8 7 , 0 0 0

9

9

9 "

"

"

4

4

4

½

½

½ "

"

"

3

2

4

4

2

6 "

"

"

¾ N P T M A L E

¾ N P T M A L E

3

3

3

0

0

0

0

0

0

P

P

P

S

S

S I

I

I

1

1

1

5

5

5

0

0

0

P

P

P

S

S

S I

I

I

7

7

8

2

9

8

L

L

L

B

B

B

S

S

S .

.

.

1

1

1

0

1

4

2

4

1

,

,

,

0

0

0

0

0

0

0

0

0

1

1

1

1

3

6

7

1

1 ,

,

,

0

0

0

0

0

0

0

0

0

3

2

0

9

9

"

"

¼ "

4

7

6

½

"

¼

"

"

6

4

4

6

6

.

7

6

"

"

5 "

¾ N P T M A L E

1 " N P T M A L E

1 ½ " N P T M A L E

1 ½ " N P T M A L E

3

3

3

0

0

0

0

0

0

P

P

P

S

S

S I

I

I

1

1

1

5

5

5

0

0

0

P

P

P

S

S

S I

I

I

1

1

2

1

4

1

0

1

0

L

L

L

B

B

B

S

S

S .

.

.

1

2

2

7

1

6

4

2

9 ,

,

,

0

0

0

0

0

0

0

0

0

1

2

3

9

4

0

8

1

1 ,

,

,

0

0

0

0

0

0

0

0

0

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.

3

SPECIFICATIONS AND PERFORMANCE RATINGS

*

*

**

**

MODEL

SSU-45DW

SSU-60DW

SSU-80DW

SSU-119DW

DIMENSIONS

HT.

DIA.

52 ½" 19 ¼"

52 ½" 23 ¼"

72"

74"

23 ¼"

27"

CAPACITY

45

60

80

119

RECOMM.

FLOW RATE

6 GPM

7 GPM

10 GPM

12 GPM

PRESSURE

DROP (FEET)

8.2

12.8

13.6

15.9

180° BOILER WATER

FIRST HOUR RATINGS

140°F 115°F

70 GAL 108 GAL

90 GAL

138 GAL

210 GAL

144 GAL

215 GAL

326 GAL

180° BOILER WATER

2ND HOUR RATINGS

140°F 115°F

40 GAL 63 GAL

50 GAL

72 GAL

110 GAL

*DOE TEST METHOD BASED ON 90°F. TEMPERATURE RISE, 50°/140° W/ BOILER WATER AT 180°F

TANK SIZE

SSU-45DW

FLOOR TO

BOILER

SUPPLY

9"

FLOOR TO

BOILER

RETURN

4 ½"

FLOOR TO

DOMESTIC

OUTPUT

46"

DOMESTIC

CONNECTIONS

¾" NPT MALE

TEST

PRESSURE

300 PSI

WORKING

PRESSURE

150 PSI

SHIPPING

WEIGHT

88 LBS.

76 GAL

113 GAL

171 GAL

180° BOILER

BTU/SIZE

107,000

SSU-60DW

SSU-80DW

9"

21"

4 ½"

6"

46"

64 ¾"

1" NTP MALE

1 ½" NPT MALE

300 PSI

300 PSI

150 PSI

150 PSI

110 LBS.

141 LBS.

176,000

208,000

SSU-119DW 22 ¼" 7 ¼" 66" 1 ½" NPT MALE 300 PSI 150 PSI 210 LBS.

231,000

NOTE: TANK RECOVERY FROM COLD START WILL BE BETWEEN 55-65 MINUTES WHEN SIZED WITH CORRECT FLOW

RATE, BOILER SIZE, AND PRESSURE DROP RATINGS FROM LIST IN ABOVE CHART.

ULTRA COMMERCIAL SERIES

M O D E L

S S U 4 5 C

D I M E N S I O N S

H T .

4 2

D I A .

2 3 ¼ "

C A P A C I T Y

H E A T E X C H .

S U R F A C E

4 5 4 0 S Q .

F T .

R E C O M M .

F L O W R A T E

2 0

P R E S S U R E

D R O P ( F E E T )

1 8 0 °

F I R S T

B O I L E R

H O U R

W A T E R

R A T I N G S *

1 4 0 ° F 1 1 5 ° F

2 0 0 °

F I R S T

B O I L E R

H O U R

W A T E R

R A T I N G S *

1 4 0 ° F 1 1 5 ° F

6 .

8 3 1 4 g a l 4 1 4 g a l 3 5 1 g a l 4 7 7 g a l

S S U 6 0 C

S S U 8 0 C

5 2 ½ "

7 2 "

2 3 ¼ "

2 3 ¼ "

6 0

8 0

4 0 S Q .

F T .

6 8 S Q .

F T .

2 2

2 4

9 .

2

1 0 .

0

3 5 4 g a l

4 9 0 g a l

4 6 7 g a l

6 4 7 g a l

3 9 6 g a l

5 4 8 g a l

S S U 1 1 9 C 7 4 " 2 7 " 1 1 9 6 8 S Q .

F T .

2 8 1 2 .

7 6 3 7 g a l 8 4 1 g a l

*DOE TEST METHOD BASED ON 90°F. TEMPERATURE RISE, 50°/140° W/ BOILER WATER AT 180°F

7 1 3 g a l

5 3 9 g a l

7 4 5 g a l

9 7 0 g a l

T A N K S I Z E

F L O O R T O

B O

S U P

I L E R

P L Y

S S U 4 5 C 9 "

F L O O R T O

B O I L E R

R E T U R N

F L O O R T O

D O M E S T I C

O U T

D O M E S T I C

C O N N E C T I O N S

T E S T

P R E S S U R E

W O R K I N G

P R E S S U R E

S H I P P I N G

W E I G H T

1 8 0 °

F I R S T

B O I L E R W A T E R

H O U

B T U

R

/ S I

R A T I N G S *

Z E

2 0 0 °

F I R S T

B O I L E R W A T E R

H O U

B T U

R

/ S I

R A T I N G S *

Z E

4 ½ " 3 5 " 1 ¾ " N P T M A L E 3 0 0 P S I 1 5 0 P S I 9 9 L B S .

2 1 5 , 0 0 0 2 4 6 , 0 0 0

S

S

S

S

U

U

-

-

6

8

0

0

C

C

9 "

2 9 "

4

6

½

"

"

6

4

4

6

.

7

"

5 " 1

1 "

½ "

N P T

N P T

M A L

M A

E

L E

3

3

0

0

0

0

P

P

S

S

I

I

1

1

5

5

0

0

P

P

S

S

I

I

1

1

1

4

5

1

L

L

B

B

S

S

.

.

2

3

4

3

5

1

,

,

0

0

0

0

0

0

2

3

7

7

0

4

,

,

0

0

0

0

0

0

S S U 1 1 9 C 3 0 ¼ " 7 ¼ " 6 6 " 1 ½ " N P T M A L E 3 0 0 P S I 1 5 0 P S I 2 1 0 L B S .

4 2 5 , 0 0 0 4 9 0 , 0 0 0

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.

CONTINUOUS FLOW PERFORMANCE CALCULATION

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

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

(FHR) (CONTINUOUS FLOW)

4

REDUCED BOILER INPUT SIZING GUIDE

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

WALL TANKS.

MODEL

S S U 2 0

S S U 3 0

S S U 3 0 L B

S S U 4 5

A

B

A

B

A

B

A

B

G R O S S O

B T U / H R

U T

200,000

—

—

—

—

—

—

—

—

G R O S S O U T

B T U / H R

220,000

—

—

—

—

—

—

—

—

G R O S S O U T

B T U / H R

240,000

—

—

—

—

—

—

—

—

G R O S S O U T

B T U / H R

260,000

—

—

—

—

—

—

—

—

G R O S S O

B T U / H R

U T

280,000

—

—

—

—

—

—

—

—

G R O S S O U T

B T U / H R

300,000

—

—

—

—

—

—

—

—

G R O S S O U T

B T U / H R

320,000

—

—

—

—

—

—

—

—

S S U 6 0

S S U 8 0

S S U 1 1 9

A

B

A

B

A

B

3 7 0

2 6 6

4 8 9

3 5 9

4 5 7

3 3 5

3 7 0

2 6 6

5 0 3

3 7 0

4 7 0

3 4 5

3 7 0

2 6 6

5 0 3

3 7 0

5 4 3

3 9 9

—

—

5 0 3

—

6 2 7

4 6 0

—

—

5 0 3

3 7 0

6 4 5

4 7 4

—

—

5 0 3

3 7 0

6 4 5

4 7 4

—

—

—

—

6 4 5

4 7 4

SUPERstor’s PRODUCT LINE CONSISTS OF VARIOUS MODELS, AVAILABLE IN DIFFERENT SIZES

CALL THE FACTORY FOR PRODUCT AND WARRANTY INFORMATION!

"DW" (double wall heat exchanger) models are available in the 45, 60, 80, and 119 U.S. gallon sizes

"CB" (coil booster) models operate in conjunction with a tankless heater, to increase hot water storage capacity. Models are available in 30, 45, 60, 80, and 119 U.S. gallon sizes.

"C" commercial models for dual systems or commercial applications; use one coil for wood boiler, the other for the oil boiler; adaptable to solar systems as well; also good for hotels, motels, and apartments. Models are available in the

45, 60, 80, and 119 U.S. gallon sizes.

5

6

PERFORMANCE AND SIZING GUIDELINES

DETERMINE AMOUNT OF DOMESTIC HOT WATER NEEDED, THEN USE THE CHARTS

BELOW TO OPTIMIZE SUPER STOR ULTRA V.S. BOILER SIZING.

COLD START BOILERS:

A. LESS THAN 90 SECONDS TO HEAT UP TO TEMPERATURE

B. GREATER THAN 90 SECONDS TO HEAT UP TO TEMPERATURE

NOTE: FIRST DRAW AT 140° F. (FOR PERFORMANCE AT 115° F, MULTIPLY BY 1.56 FOR

MINUTES OF WATER DRAW)

M O D E L

S S U 2 0

S S U 3 0

S S U 3 0 L B

S S U 4 5

S S U 4 5 C

A

B

A

B

A

B

A

B

A

B

2 .

0 G P M

9 .

5

8 .

5

1 6 .

0

1 4 .

0

1 8 .

0

1 7 .

0

2 3 .

0

1 8 .

0

4 5

4

.

0

2 .

5 G P M

8 .

0

7 .

5

1 3 .

0

1 2 .

0

1 4 .

0

1 2 .

0

1 8 .

0

1 5 .

0

4

2 4 .

0

3 .

0 G P M

7 .

0

6 .

5

1 0 .

0

9 .

0

1 2 .

0

1 0 .

0

1 4 .

0

1 3 .

0

4

2 6 .

0

3 .

5 G P M

5 .

5

5 .

0

7 .

5

7 .

0

9 .

0

8 .

0

1 1 .

0

1 0 .

0

2 9 .

0

1 8 .

0

4 .

0 G P M

4 .

5

4 .

0

6 .

0

5 .

5

6 .

5

6 .

0

8 .

5

7 .

5

2 0 .

0

1 6 .

0

4 .

5 G P M

4 .

0

3 .

5

5 .

5

5 .

0

6 .

0

5 .

5

7 .

5

7 .

5

1 7 .

0

1 3 .

0

5 .

0 G P M

3 .

5

3 .

0

5 .

0

4 .

5

5 .

5

5 .

0

7 .

0

6 .

5

1 4 .

0

1 0 .

0

3 6 .

0

2 9 .

0

3 0 .

0

1 9 .

0

4 6 .

0

3 0 .

0

2 2 .

0

1 2 .

0

2 9 .

0

2 1 .

0

S S U 6 0

S S U 6 0 C

A

B

A

B

S S U 8 0

S S U 8 0 C

A

B

A

B

S S U 1 1 9

S S U 1 1 9 C

A

B

A

B

NOTE: THIS INFORMATION IS BASED ON BOILER SIZE CONFORMING TO THE MINIMUM

BTU/H REQUIRED TO ACHIEVE FIRST HOUR RATINGS, OBTAINABLE FROM CHART

ABOVE.

4 indicates infinity (continous duty)

LOCATION AND OPERATION

NOTE: MINIMUM BTU/H REQUIRED TO ACHIEVE FIRST HOUR RATING

MODEL GROSS OUTPUT

SSU-20

SSU-30

SSU-30LB

SSU-45

SSU-45C

84,000

102,000

113,000

141,000

215,000

140° F 90° F

∆T

GAL/HR

121

154

169

212

314

127° F 77° F

∆T

GAL/HR

140

180

198

248

367

115° F 65° F

∆T

GAL/HR

168

212

234

292

414

SSU-60

SSU-60C

SSU-80

SSU-80C

SSU-119

SSU-119C

174,000

245,000

212,000

331,000

269,999

425,000

266

354

330

490

423

637

311

414

386

573

495

745

370

467

440

647

564

841

LOCATION

Choose a location for your water heater centralized to the piping system. You must also locate the Super Stor Ultra where it will not be exposed to freezing temperatures.

Additionally, you will need to place the water heater so that the controls, drain, and inlet/outlets are easily accessible. This appliance must not be installed outdoors, as it is certified as an indoor appliance, and must also be kept vertical on a level surface.

CAUTION

This unit must be placed where leakage from the relief valve, leakage from the related piping, or leakage from the tank or connections, will not result in damage to the surrounding areas, or to the lower floors of the building. A water heater should always be located in an area with a floor drain or installed in a drain pan suitable for water heaters. Heat Transfer Products Inc. shall not be held liable for any such water damage.

DANGER

This water heater must not be located near flammable liquids such as Gasoline,

Adhesives, Solvents, Paint Thinners, Butane, Liquefied Propane, etc.; as the controls of this appliance could ignite vapors causing an explosion.

OPERATING YOUR SUPER STOR ULTRA

“Boiler high limit should be at least 20° higher than the Super Stor Ultra temperature. Set the low limit of the boiler control at the minimum setting – this will call the burner on, only to satisfy the tank control. The differential should be 10° to 15°, if your control is adjustable, be sure that it is in that range. We recommend a temperature setting of 119°F, or in accordance with local and state codes for normal operation. You may prefer a setting of either higher or lower temperature, to satisfy your needs. A mixing valve in connection with a high temperature setting may be used for high demand applications (spas, hot tubs, whirlpools)”

7

8

PLUMBING

CAUTION

Risk of scald injury increases as you increase water temperature! If draining of the

SuperStor Ultra is necessary, open the T & P valve or a hot water tap, to prevent vacuum buildup in the tank and piping.

PLUMBING

It is mandatory that all plumbing is done is accordance with all local and state plumbing codes, or warranty will be voided. It is also necessary on all mechanical connections, that you use both thread tape and pipe dope.

NOTE: WHEN FILLING THE SUPER STOR ULTRA, MAKE SURE THAT YOU OPEN THE HOT

WATER TAP TO RELEASE AIR IN THE TANK AND PIPING.

BOILER CONNECTIONS

Use a 1" nominal minimum tube size, wherever you are using zone valves or circulators; where a 1" zone valve and 1" tube is required.

On the tank, the boiler supply is to be connected to the outlet of the circulator. The inlet of the circulator is to be connected to the “HOT OUTLET” side of the boiler. Be sure that the arrow on the circulator is facing toward the flow direction, (See pressure drop sizing for circulator, page 8). On the tank, the boiler return is to be connected to the return side of the boiler. The return(s) from heating loop(s) should have a flow check or swing check valve installed before the return pipe from the tank.

In a steam boiler, the tank supply must be connected to the boiler, well below the minimum water level. A strainer and a drain valve should be installed at the boiler for periodic draining of scale and sludge. Banging and steam bound traps will occur if the boiler water supplied to heat exchange has steam, or is slightly above the low water cut-out.

It is possible to use live steam in the heat exchanger of the Super Stor Ultra 80 and Super

Stor Ultra 119 only. Consult factory for suggested piping and required components. The

Ultra commercial series Super Stor Ultra 80C and Super Stor Ultra 119C are also included in this application.

DANGER

Water temperature over 125° F. can cause severe burns instantly, or death from scalds. Children, disabled, and elderly are at highest risk of being scalded. See instruction manual before setting temperature at water heater. Feel water before bathing or showering! Temperature limiting valves are available.

WARNING

Never use dielectric unions or galvanized steel fittings on any domestic water connections. Use only copper or brass fittings. Teflon thread sealant must be used on all connections.

PLUMBING AND WIRING

COLD WATER INLET

Use both thread tape and pipe dope and connect an NPT brass tee. On the run, install a brass drain valve. In the branch, install an NPT male X ¾ “ (minimum) tube adapter. A shut off valve between city water supply and tank inlet is recommended for ease of service at a later date. It may be recommended to use a back flow preventer – check your local codes

If a back flow preventer, or a 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 Ultra tank.

CAUTION

DO NOT PLUG TUBE OUTLET IN TANKLESS COIL.

DOMESTIC HOT WATER OUTLET CONNECTION

Use both thread tape and pipe dope, and connect an NPT brass tee. In the run of the brass tee, install an NPT brass T & P valve long element, for hot water storage tanks (Required by local codes, but not less than the valve certified as meeting the requirements for relief valves for hot water heaters (ANSI Z212B-1984), by a nationally recognized lab that maintains periodic inspection of production listed equipment. Make sure that the relief valve is sized to the

BTU/Hour capacity and storage capacity of the water heater. The temperature and pressure relief valve must be plumbed down so discharge can exit only 6” above, or at any distance below the structural floor; and cannot be in contact with any live electrical parts.

WARNING

Following installation of the T & P Relief Valve, the valve lever MUST be operated AT

LEAST ONCE A YEAR by the water heater owner to ensure that waterways are clear.

Certain naturally occurring mineral deposits may adhere to the valve, blocking waterways, rendering it inoperative. When the lever is operated, hot water will discharge if the waterways are clear. PRECAUTIONS MUST BE TAKEN TO AVOID

PERSONAL INJURY FROM CONTACT WITH HOT WATER AND TO AVOID PROPERTY

DAMAGE. BEFORE operating lever, check to see that a discharge line is connected to the valve, directing the flow of hot water from the valve to a proper place of disposal. If no water flows when the lever is operated, replacement of the valve is required. TURN

THE WATER HEATER “OFF” AND CALL A PLUMBER IMMEDIATELY.

This device is designed for emergency safety relief and shall not be used as an operating control. A relief valve functions, in an emergency, by discharging water.

Therefore, it is essential that a discharge line be piped from the valve in order to carry the overflow to a safe place of disposal. The discharge line must be same size as the valve outlet must pitch downward from the valve and terminate at least 6" above a drain where any discharge will be clearly visible.

9

PLUMBING AND WIRING

CAUTION

RE-INSPECTION OF T&P RELIEF VALVES: Temperature and Pressure Relief Valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced, if

necessary, by a licensed plumbing contractor or qualified service technician, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve and its components over time, rendering the valve inoperative. Such conditions can only be detected if the valve and its components are physically removed and inspected. Do not attempt to conduct an

inspection on your own. Contact your plumbing contractor for a re-inspection to assure continuing safety.

DANGER

WARNING: FAILURE TO RE-INSPECT THIS VALVE AS DIRECTED COULD RESULT IN

UNSAFE TEMPERATURE OR PRESSURE BUILDUP WHICH CAN RESULT IN SERIOUS

INJURY OR DEATH AND/OR SEVERE PROPERTY DAMAGE.

(Optional to save additional energy dollars) In the bottom of the tee (branch) vertically down, install an NPT tube adapter. Then install two sweat street 90° elbows. This acts as a thermal loop to prevent thermal siphon action of hot water

EXPANSION TANK

A thermal expansion tank may be required in the system designed for potable water use, to offset the expansion of stored water as the temperature is elevated (only in systems where there is no return valve, a back flow preventer, a water meter, or anywhere pressure can build up as the water is heated). See typical expansion tank on following page.

CONTROL

Install control element into well and tighten in place with screws on control body. Thermal conductive paste is recommended. Once the control is operational, it is very important to make sure the control is maintaining the desired operating temperature.

WIRING

All wiring is to be done in accordance with all applicable local and state codes. Turn off all power related to the boiler starting and wiring procedures. It is recommended that a disconnect switch be installed between the boiler control and water heater.

10

PLUMBING AND WIRING

PRESSURE DROP SIZING FOR CIRCULATOR

You must have a flow rate, from chart on page 3, on the boiler circulator for the water; or the published ratings cannot be achieved. The chart below represents the tube run and the water heater ONLY, and does not include any flow checks or zone valves. That resistance must be added to the value found in the chart below.

T

P R

1 "

E S

C

S

O

U R

P P

E D R O P

E R

E L B O W S ,

,

A

A N D

N D

F O R

F

O N

O R

T

T U

S

E E

I

B E

X

O

9

N

L

0

T

E N

D E

H E

G T H

G

R

R

U N

O

E E

F

U B E S I Z E 2 0 ' 3 0 ' 4 0 ' 5 0 ' 6 0 '

6 G P M

7 G P M

1 0 G P M

1 2 G P M

1 4 G P M

1 4 G P M

1

8

1

1

1

1

0

.

1

6

.

.

2

1 .

5

5 .

.

3

3

3

3

3

5

'

'

'

'

'

'

1

8

1

1

1

1

1

.

9

1 .

3 .

6

6

.

7

.

.

3

1 '

2 '

4

4

7

'

'

'

' 1

1

9

1

1

1

2

.

2

1 .

9

4 .

1

7

7

.

2

3

.

5

.

5

5 '

'

'

4

'

'

'

9

1

1

1

1

.

5

1

2

3

.

7

2 .

8

8

8

5 '

.

6

.

6 '

'

'

'

'

9 .

8 '

1 3 .

1 '

1 3 .

6 6 '

1 6 '

1 9 .

8 '

1 9 .

8 '

1

P R

¼ "

E S S U R E

C O P P E R ,

D R O P

T E N 9

F

0

O

°

R

E L

T U

B O

B E

W

L E N G T H

S A N D 2

O F

T E E S

T U

2

B

2 4

8

E

G

S I Z

2 0 G P M

2 2 G P M

G P M

P M

E 2 0 '

1 0 .

9 '

1 4 .

0 '

1 6 .

2 '

2 0 .

4 '

3 0 '

1 1 .

7 '

1 5 .

0 '

1 7 .

5 '

2 2 .

0 '

4

2 3

0 '

1 2 .

6 '

1 6 .

0 '

1 8 .

8 '

.

6

5 0 '

1 3 .

4 '

1 7 .

0 '

2 0 .

1 '

2 5 .

2

6 0 '

1 4 .

3 '

1 8 .

0 '

2 1 .

5 '

2 6 .

8

11

TYPICAL MIXING VALVE

TYPICAL INSTALLATIONS

TYPICAL EXPANSION TANK

12

TYPICAL INSTALLATION USING ZONE VALVES

TYPICAL INSTALLATION USING CIRCULATORS

TYPICAL INSTALLATIONS

TYPICAL INSTALLATION USING A ZONE VALVE (3-WAY)

13

TYPICAL DP INSTALLATIONS

TYPICAL INSTALLATIONS

14

SUPERSTOR WITH STORAGE TANK TYPICAL INSTALLATION

MULTIPLE TANK INSTALLATIONS

TYPICAL INSTALLATIONS

TYPICAL STEAM BOILER

15

ZONING WITH CIRCULATORS WITH R845 RELAY

WIRING DIAGRAMS

16

ZONING WITH CIRCULATORS USING R8182D AND D.P.S.T. NO RELAY REQUIRED

WIRING DIAGRAMS

ZONING WITH CIRCULATORS USING L8124 A, C AND R845A RELAY

ZONING WITH CIRCULATORS USING L8124 E,F AND D.P.S.T. CONTROL. (NO RELAY REQUIRED)

17

18

ZONING WITH CIRCULATORS WITH R182D AND R845A RELAY

WIRING DIAGRAMS

USING CONTROL WITH BUILT IN IDPST SWITCH WITH NO RELAY REQUIRED

WIRING DIAGRAMS

ZONING WITH CIRCULATORS USING L8124 A, C AND R845A RELAY

ZONING WITH CIRCULATORS USING L8124 A,C AND D.P.S.T. (NO RELAY REQUIRED)

19

20

WIRING DIAGRAMS

USING L8148A OR L8152A COLD START BOILER CONTROL WITH CIRCULATORS

PRIORITY ZONE WITH CIRCULATORS

WIRING DIAGRAMS

USING L8148A OR L8152A COLD START BOILER CONTROL WITH ZONE VALVES

PRIORITY ZONE WITH ZONE VALVES

21

TROUBLESHOOTING

TROUBLESHOOTING YOUR SUPER STOR ULTRA

NO HOT WATER

P R O B L E M :

A .

Z O N E V A L V E N O T O P E N I N G

B .

C I R C U L A T O R N O T O P E R A T I N G

C .

T A N K C O N T R O L S E T T O O L O W

D .

B O I L E R C O N T R O L S E T T O O L O W

E .

W I R I N G I N C O R R E C T

F .

T A N K C O N T R O L F A I L U R E

G .

Z O N E V A L V E F A I L U R E

H .

C I R C U L A T O R F A I L U R E

I .

A I R T R A P I N L O O P

P O S S I B L E S O L U T I O N

A .

O P E N M A N U A L L Y T O C H E C K

B .

C H E C K O R R E P L A C E

C .

R A I S E T A N K T E M P E R A T U R E ( S E E W A R N I N G T H I S S E C T I O N )

D .

R A I S E B O I L E R T E M P E R A T U R E

E .

R E C H E C K W I R I N G

F .

R E P L A C E C O N T R O L

G .

R E P L A C E V A L V E

H .

R E P L A C E C I R C U L A T O R

I .

P U R G E T O R E M O V E A I R

NOT ENOUGH HOT WATER

P R O B L E M :

A .

Z O N E V A L V E R E S T R I C T I O N

B .

C I R C U L A T O R A R R O W R E V E R S E D

C .

T A N K T E M P E R A T U R E T O O L O W

D .

B O I L E R T E M P E R A T U R E T O O L O W

E .

B O I L E R S I Z E D T O O S M A L L

F .

D E M A N D F L O W R A T E T O O H I G H

G .

T A N K S I Z E D T O O S M A L L

H .

D E M A N D F L O W R A T E T O O H I G H

I .

A I R T R A P I N L O O P

I .

A I R T R A P I N L O O P

J .

H E A T & T A N K C O M E O N T O G E T H E R

K .

N O T E N O U G H S P A C E H E A T

L .

S L O W R E C O V E R Y

P O S S I B L E S O L U T I O N

A .

1 " F U L L B O R E R E P L A C E Z O N E V A L V E

B .

R E V E R S E C I R C U L A T O R

C .

* * * R A I S E T A N K T E M P E R A T U R E ( S E E W A R N I N G T H I S S E C T I O N )

D .

R A I S E B O I L E R T E M P E R A T U R E

E .

C H E C K S I Z I N G C H A R T

F .

C H E C K S I Z I N G C H A R T

G .

C H E C K S I Z I N G C H A R T

H .

I N S T A L L M I X I N G V A L V E , R A I S E T A N K T E M P ( S E E W A R N I N G T H I S S E C T I O N )

I .

P U R G E T O R E M O V E A I R

I N S T A L L F L O W R E G U L A T O R

I .

P U R G E T O R E M O V E A I R

J .

R E C H E C K W I R I N G O R C O I N C I D E N C E

D R A W T A N K D O W N A N D L O W E R H E A T T H E R M O S T A T .

R E C H E C K

K .

B O I L E R S I Z E D T O O S M A L L , C O N S U L T C H A R T

L .

C I R C U L A T O R H E A D C A P A C I T Y T O O L O W

T & P VALVE DISCHARGES

P R O B L E M :

A .

Z O N E V A L V E R E S T R I C T I O N

B .

C I R C U L A T O R A R R O W R E V E R S E D

C .

T A N K T E M P E R A T U R E T O O L O W

D .

B O I L E R T E M P E R A T U R E T O O L O W

E .

B O I L E R S I Z E D T O O S M A L L

F .

D E M A N D F L O W R A T E T O O H I G H

G .

T A N K S I Z E D T O O S M A L L

H .

D E M A N D F L O W R A T E T O O H I G H

I .

A I R T R A P I N L O O P

I .

A I R T R A P I N L O O P

J .

H E A T & T A N K C O M E O N T O G E T H E R

K .

N O T E N O U G H S P A C E H E A T

L .

S L O W R E C O V E R Y

P O S S I B L E S O L U T I O N

A .

1 " F U L L B O R E R E P L A C E Z O N E V A L V E

B .

R E V E R S E C I R C U L A T O R

C .

R A I S E T A N K T E M P E R A T U R E ( S E E W A R N I N G T H I S S E C T I O N )

D .

R A I S E B O I L E R T E M P E R A T U R E

E .

C H E C K S I Z I N G C H A R T

F .

C H E C K S I Z I N G C H A R T

G .

C H E C K S I Z I N G C H A R T

H .

I N S T A L L M I X I N G V A L V E , * * * R A I S E T A N K T E M P ( S E E N O T E B E L O W )

I .

P U R G E T O R E M O V E A I R

I N S T A L L F L O W R E G U L A T O R

I .

P U R G E T O R E M O V E A I R

J .

R E C H E C K W I R I N G O R C O I N C I D E N C E

D R A W T A N K D O W N A N D L O W E R H E A T T H E R M O S T A T .

R E C H E C K

K .

B O I L E R S I Z E D T O O S M A L L , C O N S U L T C H A R T

L .

C I R C U L A T O R H E A D C A P A C I T Y T O O L O W

22

TROUBLESHOOTING

HOT TUBS, SPAS, MULTIPLE SHOWERS, HIGH DEMAND

P R O B L E M :

A .

N O T E N O U G H H O T W A T E R

B .

P R E S S U R E T O O L O W

C .

R E C O V E R Y O F T A N K S L O W

D .

N O T E N O U G H H O T W A T E R

P O S S I B L E S O L U T I O N

A .

C H E C K F L O W R A T E A N D C O M P A R E T O C H A R T

B .

C H E C K L I N E P R E S S U R E F O R R E S T R I C T I O N

C .

S L O W S T A R T U P B O I L E R , S E E C H A R T

D .

B O I L E R S I Z E D T O O S M A L L , S E E C H A R T

I

D E M A

*

N

*

S

*

T

R

A

A I

N D

L L

S E

T

M

T

I

O

X

A

I

O G R

N G

N K A

E

N

A

D

T ,

B

C

V A L V E

O

H

I

A

L

E

E

C

N D

R

K F L

O R

T E

O W

A

M P

F

E

R

L

R

A T

O

A

W

E S

T U

R E

R E

A

S

N

T

( S

D

R

E

I

C O

C T I

M P

N G

A R T T O

V A L V E

E W A R N I N G

C H A

A N D

T H I S

R T .

S E C T I O N ) .

WARNING

When raising tank temperature, you increase the risk of scalding – Please use a water tempering or mixing valve and extreme caution. Consult codes for conformance.

23

© Copyright 2006, 2005 Heat Transfer Products, Inc.

LP-83 REV. 1/1/07