Installation, Operation, and Maintenance Manual SuperTherm (VS Series) Indirect Fired, Semi-Instantaneous, Steam and Boiler Water Heater (Vertically Built, Steam to Water with Electronic or Pneumatic Controls) This manual applies to the following models: SuperTherm VS06_S2A SuperTherm VS08_S2A SuperTherm VS010_S2A SuperTherm VS012_S2A SuperTherm VS06_D2A SuperTherm VS08_D2A SuperTherm VS010_D2A SuperTherm VS012_D2A CONTRACTOR / FACILITY INFORMATION NOTE: This user manual must always accompany the specific unit as recorded below: Model #: _______________________________ Serial #: _______________________________ Install Date: ____________________________ DHT SUPERTHERM WATER HEATER Latest Update: 09/05/2018 DISCLAIMER The information contained in this document is subject to change without notice from Diversified Heat Transfer, Inc. (DHT). DHT makes no warranty of any kind in respect to this material, including, but not limited to, implied warranties of merchantability and fitness for a particular application. DHT is not liable for errors appearing in this document, nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of these materials. REV-3 Diversified Heat Transfer, Inc. 439 Main Road, Route 202 Towaco, New Jersey 07082 Page 1 of 90 SuperTherm Manual Phone: 800-221-1522 Website: www.dhtnet.com 02/24/2018 SUPERTHERM Install, Operation, and Maintenance Manual TABLE OF CONTENTS TABLE OF CONTENTS: SECTION 1: GENERAL INFORMATION .................................................................................................... 4 1.1 INTRODUCTION ........................................................................................................................................... 4 1.2 DESCRIPTION .............................................................................................................................................. 4 1.3 FEATURES .................................................................................................................................................... 5 1.4 APPLICATIONS............................................................................................................................................. 5 1.5 ENERGY SOURCES ..................................................................................................................................... 6 1.6 DESIGN CONDITIONS ................................................................................................................................. 6 1.7 CONSTRUCTION .......................................................................................................................................... 6 1.8 SAFETY ......................................................................................................................................................... 7 1.8.1 Operating Precautions ............................................................................................................................................. 7 1.8.2 Storage and Transportation..................................................................................................................................... 7 1.8.3 Safety Features ........................................................................................................................................................ 7 1.8.4 Safety Notation ........................................................................................................................................................ 8 1.8.5 Proper Training ........................................................................................................................................................ 8 1.8.6 Safety Precautions ................................................................................................................................................... 8 SECTION 2: INSTALLATION INSTRUCTIONS ....................................................................................... 10 2.1 RECEIVING, HANDLING, AND STORAGE ................................................................................................ 10 2.1.1 Examining the Unit ................................................................................................................................................ 10 2.1.2 Compliance with Codes ......................................................................................................................................... 10 2.2 SITE PREPARATION .................................................................................................................................. 11 2.3 INSTALLATION CLEARANCES AND UNIT DIMENSIONS ....................................................................... 11 2.4 PLACEMENT ............................................................................................................................................... 15 2.5 LOOSE PART INSTALLATION INSTRUCTIONS ....................................................................................... 16 2.5.1 PART 1: DHW Outlet Pressure Relief Valve Installation ........................................................................................ 17 2.5.2 PART 2: Steam Inlet Piping Assembly Installation ................................................................................................. 17 2.5.3 PART 3: Condensate Trap Connection Instructions ............................................................................................... 18 2.6 PIPING INSTALLATION AND UNIT CONNECTIONS ................................................................................ 19 2.7 ELECTRICAL CONNECTIONS ................................................................................................................... 21 2.8 PNEUMATIC DEVICES INSTALLATION .................................................................................................... 22 2.9 WATER QUALITY ....................................................................................................................................... 23 SECTION 3: OPERATION AND CONTROLS .......................................................................................... 24 3.1 INTRODUCTION ......................................................................................................................................... 24 3.2 SUPERTHERM FUNCTIONAL DESCRIPTION .......................................................................................... 24 3.3 PREPARATION OF UNIT FOR OPERATION ............................................................................................ 28 3.4 UNIT STARTUP PROCEDURES ................................................................................................................ 28 3.5 UNIT SHUTDOWN PROCEDURES ............................................................................................................ 29 3.6 CONTROLLER INTRODUCTION ............................................................................................................... 29 3.7 CONTROLLER STARTUP .......................................................................................................................... 30 3.8 PROGRAMMING THE SEQUENCE ........................................................................................................... 31 SECTION 4: MAINTENANCE ................................................................................................................... 35 4.1 CIRCULATING PUMP MAINTENANCE ..................................................................................................... 36 4.2 POWER CONNECTION REWIRING .......................................................................................................... 37 4.3 PNEUMATIC (INSTRUMENT AIR) CONNECTIONS REFITTING ................................................................................ 37 4.4 HEAT EXCHANGER COIL & GASKET MAINTENANCE ........................................................................... 38 4.5 INLET, OUTLET, AND CONDENSATE / WATER RETURN LINE AND MANUAL SHUTOFF VALVES Page 2 of 90 Diversified Heat Transfer, Inc. 439 Main Road Towaco, New Jersey 07082 REV-3 02/24/2018 Phone: 800-221-1522 Website: www.dhtnet.com SuperTherm Manual SUPERTHERM Install, Operation, and Maintenance Manual TABLE OF CONTENTS REPLACEMENT ................................................................................................................................................ 40 4.6 PRESSURE GAUGE (ENERGY SOURCE) REPLACEMENT ................................................................... 41 4.7 PRESSURE OR T&P RELIEF VALVE (SHELL/TANK) REPLACEMENT ....................................................................... 42 4.8 SOLENOID SAFETY SYSTEM INSPECTION & REPLACEMENT ............................................................................... 42 4.9 STRAINERS INSPECTION AND REPLACEMENT .................................................................................... 44 4.10 TEMPERATURE CONTROL VALVE INSPECTION & REPLACEMENT ...................................................................... 45 4.11 TEMPERATURE CONTROLLER .............................................................................................................. 46 4.12 TRAPS (MAIN & AUXILIARY) REPLACEMENT ....................................................................................... 46 (STEAM SYSTEMS ONLY) ..............................................................................................................................