PEERLESS PT-30, PT-40, PT-60, PT-80, PT-50 Installation, Operation & Maintenance Manual

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Page 1

Partner

Water Heater

PT-30 PT-40 PT-50 PT-60 PT-80 PT-120

Peerless

Indirect-Fired

Installation, Operation & Maintenance Manual

Page 2

USING THIS MANUAL 1

A. INSTALLATION SEQUENCE . . . . . . . . . . . . . .1

B. SPECIAL ATTENTION BOXES . . . . . . . . . . . . .1

PRODUCT & SAFETY INFORMATION 2

1. PREINSTALLATION 3

A. CODES COMPLIANCE . . . . . . . . . . . . . . . . . . .3

B. CODES RESTRICTIONS . . . . . . . . . . . . . . . . . .3

C. OPERATING RESTRICTIONS . . . . . . . . . . . . . .3

D. LOCATING WATER HEATER . . . . . . . . . . . . . .3

E. PRODUCT SELECTION . . . . . . . . . . . . . . . . . .4

F. RECOMMENDED CLEARANCES . . . . . . . . . . .5

2. INSTALLATION - PIPING 6

A. TEMPERATURE & PRESSURE (T&P)

RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . .6

B. DRAIN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . .6

C. AUTOMATIC AIR VENT . . . . . . . . . . . . . . . . . .7

D. THERMAL EXPANSION . . . . . . . . . . . . . . . . .7

E. WATER HAMMER . . . . . . . . . . . . . . . . . . . . . .7

F. VACUUM BREAKER . . . . . . . . . . . . . . . . . . . . .7

G. GENERAL PIPING . . . . . . . . . . . . . . . . . . . . . . .7

H. DOMESTIC PIPING . . . . . . . . . . . . . . . . . . . . . .7

I. THERMOSTATIC MIXING VALVE . . . . . . . . . .8

J. RECIRCULATION PIPING . . . . . . . . . . . . . . . . .8

K. MULTIPLE WATER HEATER SYSTEMS . . . . .8

L. BOILER PIPING . . . . . . . . . . . . . . . . . . . . . . . . .8

3. INSTALLATION - PIPING DRAWINGS 9

4. INSTALLATION - WIRING 16

A. WIRING REQUIREMENTS . . . . . . . . . . . . . . .16

B. CIRCULATORS . . . . . . . . . . . . . . . . . . . . . . . .16

C. ZONE VALVES . . . . . . . . . . . . . . . . . . . . . . . .16

D. SNAPSET CONNECTION . . . . . . . . . . . . . . . .16

5. INSTALLATION - WIRING DRAWINGS 17

6. WATER HEATER START-UP 22

A. FILLING THE INNER (DOMESTIC WATER)

TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

B. FILLING THE OUTER (BOILER WATER)

TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

C. GENERAL NOTES . . . . . . . . . . . . . . . . . . . . .23

D. ADJUSTING THE WATER HEATER

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . .23

7. WATER HEATER MAINTENANCE 24

A. MAINTENANCE SCHEDULE . . . . . . . . . . . . .24

B. FILLING WATER HEATER . . . . . . . . . . . . . . .24

C. DRAINING WATER HEATER . . . . . . . . . . . . .24

D. DRAINING INNER (DOMESTIC WATER)

TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

E. DRAINING OUTER (BOILER WATER)

TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

8. TROUBLESHOOTING 26

9. REPAIR PARTS 27

10. WATER HEATER DIMENSIONS & RATINGS 29

11. PERFORMANCE RATINGS 30

TABLE OF CONTENTS

Page 3

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 boiler installation.

B. SPECIAL ATTENTION BOXES

Throughout this manual special attention boxes are provided to supplement the instructions and make special notice of potential hazards. The definition of each of these categories, in the judgement of PB Heat, LLC are as follows:

USING THIS MANUAL

Indicates special attention is needed, but not directly related to potential personal injury or property damage.

NOTICE

Indicates a condition or hazard which will or can cause minor personal injury or property damage.

CAUTION

DANGER

Indicates a condition or hazard which will cause severe personal injury, death or major property damage.

Indicates a condition or hazard which may cause severe personal injury, death or major property damage.

WARNING

USING THIS MANUAL

Page 4

PRODUCT SAFETY & INFORMATION

DANGER

HOT WATER CAN SCALD!

• Water temperatures over 125ºF can cause severe

burns instantly or death from scalding.

• Children, disabled and elderly are at highest risk of being scalded.

• Never leave them unattended in or near shower, bathtub or sink.

• Never allow small children to use a hot water faucet or draw their own bath.

• If anyone using hot water in the building fits the above description or if local codes or state laws require specific water temperatures at hot water faucet, it is recommended:

– to install a thermostatic mixing valve at this

appliance or at each water faucet.

– to set the thermostat knob for the lowest

temperature which satisfies your hot water needs.

• Water drained from the system drain valves may be extremely hot. To avoid injury:

– Make sure all connections are tight.

– Direct water flow away from any person.

Protection must be taken against excessive temperature and pressure!

• Installation of a Temperature & Pressure (T&P) relief valve is required.

WARNING

To prevent damage to the inner tank, the installer must:

• Always fill inner tank prior to outer tank and always drain outer tank prior to inner tank.

• Relieve primary system pressure below 15 psig prior to draining inner tank.

CAUTION

Page 5

1. PREINSTALLATION

A. CODES COMPLIANCE

Water heater installation must conform with the instructions in this manual and where applicable:

• local, state, provincial, and national codes, laws, regulations and ordinances.

• in Canada - CAN / CGA B149.1 or B149.2 Installation Code.

Peerless

Partner®water heaters are exempt from ASME Section VIII, Division 1 Code construction per Interpretation VIII-86-136. Check with local codes for applicability.

Where recommendations in this manual differ from local, or national codes, the local or national codes take precedence.

B. CODES RESTRICTIONS

1. Single wall heat exchanger in the Peerless®Partner

water heater complies with National Standard Plumbing Code, provided that:

a. boiler water (including additives) is practically

non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, and

b. boiler water pressure is limited to maximum 30

psig by approved relief valve.

2. Single wall heat exchangers are permitted under the

Uniform Plumbing code - Paragraph L3.2. and L3.3 if they satisfy all of the following requirements.

a. The heat transfer medium is potable water or

contains only substances which are recognized as safe by the U.S. Food and Drug Administration.

b. The pressure of the heat transfer medium is

maintained less than the normal minimum operating pressure of the potable water system

Exception: Steam complying with section #1 above.

c. 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 the Administrative Authority.

C. OPERATING RESTRICTIONS

1. Maximum domestic hot water temperature is 194ºF for commercial applications and 140ºF for residential applications.

2. Maximum boiler water temperature is 210ºF.

3. Maximum working pressure for inner (domestic water) tank is 150 psig.

4. Maximum working pressure for outer (boiler water) tank is 45 psig.

5. pH and chloride limits for water heaters are:

a. chloride, less than 150 mg/l (ppm)

b. pH value min. 6 - max. 8

D. LOCATING WATER HEATER

1. This water heater is not intended for outdoor installations.

2. Keep distance between boiler and water heater to a minimum to:

a. reduce piping heat loss

b. provide minimal friction loss

3. Locate water heater so that any leakage from the tank or water connections will not cause damage to the area adjoining the water heater or to lower floors in the structure.

When such a location is unavoidable, a suitable drain pan with adequate drainage, should be placed under the water heater.

4. The Peerless

Partner®water heaters are designed for

vertical installation only.

Peerless®Partner®water heaters will absorb 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.

NOTICE

Do not install the water heater on any application if the boiler piping contains non-oxygen barrier tubing or if the boiler piping is considered an “open system”. Exposing the outer tank of the water heater to oxygen contamination will lead to premature tank failure and denial of the warranty.

NOTICE

Any water conditioning system must be installed and maintained in accordance with manufacturer’s specifications.

NOTICE

PREINSTALLATION

Page 6

E. PRODUCT SELECTION

1. The following guidelines apply to residential systems only. For commercial or institutional installations contact your local PB Heat, LLC representative.

2. Determine the quantity of domestic hot water required. Factors to consider:

a. Estimate typical peak hour demand. Determine

the general time of day (morning, noon, evening) when the most hot water is used. Use chart below to determine potential maximum usage.

b. Estimate unusual peak draw demand.

Whirlpool baths, hot tubs, and multiple head showers require large quantities of hot water in a short period of time. Contact fixture manufacturer for quantity of water required. Generally speaking, these circumstances can only be met with larger storage volumes.

c. Domestic Water Temperature. Most residential

usage will be satisfied with 119°F water, the temperature setting recommended by the Consumer Product Safety Commission. Some applications such as laundry and dishwashers may require a higher temperature.

Ratings can be improved by increasing Peerless

Partner®thermostat setting and using a mixing valve to temper the hot water to the proper temperature. When temperatures greater than 119°F are required, use a mixing valve at the outlet of the water heater or anti-scald fittings at point of use.

d. Domestic water priority. First hour ratings may

be less than published when boiler output is shared with space heating. Generally a consumer will notice a drop in domestic water temperature before a drop in space heating temperature. Giving domestic water production priority by directing entire boiler output to Peerless

Partner

will maximize domestic water output. However, prioritization controls could result in an unacceptable drop in space heating temperature when large quantities of domestic hot water are used, and a prioritization control malfunction could result in loss of space heating.

3. Multiple Water Heaters. Peak domestic water usage (first hour rating) or unusual peak draw may not be met with a single water heater. Multiple units can be installed as either a bank of tanks acting as a single unit, or as multiple individual units sized and located for specific draw situations.

PREINSTALLATION

Estimate of Peak Domestic Hot Water Usage

Average Gallons of Times Used During Gallons Used in

Use Hot Water per Usage One Hour One Hour

Shower 20 x _____________ = _____________

Bath 20 x _____________ = _____________

Shaving 2 x _____________ = _____________

Hands and Face Washing 4 x_____________ = _____________

Hair Shampoo 4 x_____________ = _____________

Hand Dish Washing 4 x _____________ = _____________

Automatic Dish Washing 14 x _____________ = _____________

Food Preparation 5 x_____________ = _____________

Wringer Clothes Washer 26 x _____________ = _____________

Automatic Clothes Washer 32 x _____________ =

Total Peak Hour Demand = __________

The Peerless®Partner®indirect-fired water heater is deemed to be used in a "commercial setting" if at any time the unit is operated at a temperature over 150°F. Refer to warranty for additional information.

NOTICE

DANGER

Water temperatures over 125°F can cause severe burns instantly, or death from scalds.

Children, disabled, and elderly are at the highest risk of being scalded.

See instruction manual before setting temperature at water

heater. Feel water before bathing or showering. Temperature limiting valves are available, see

manual.

Page 7

PREINSTALLATION

F. RECOMMENDED CLEARANCES

1. Water heater should be installed to allow adequate clearance for servicing.

2. Zero clearance is permissible to any side of the Peerless

Partner®water heater, but information labels

may be hidden.

3. Recommended top or vertical clearance is 12" minimum.

4. Refer to boiler manual for boiler clearances.

5. See Figure 1.1 for recommended service clearances.

Figure 1.1: Recommended Clearances

Page 8

2. INSTALLATION – PIPING

A. TEMPERATURE & PRESSURE (T&P)

RELIEF VALVE

1 Every Peerless®Partner®water heater must be

protected with a T&P relief valve.

2 Determine T&P relief valve size by the following

specifications, unless they conflict with local codes:

a. Peerless

Partner®30/40/50: 3/4" NPT with an AGA Rating of 100,000 BTU/hr and a maximum pressure rating of 150 psig. (Watts 100XL-8 or equivalent).

b. Peerless

Partner®60/80/100/120: 3/4" NPT with an AGA Rating of 200,000 BTU/hr and a maximum pressure rating of 150 psig. (Watts 40XL-8 or equivalent).

3. Standard Installation: Install T&P relief valve in the Auxiliary connection located behind the air vent on the top of the water heater (Figure 3.1).

Install the T&P relief valve in the run (straight through leg) of a tee located at the domestic hot water outlet when using the Auxiliary connection for a recirculation return (Figure 3.2).

4. Commonwealth of Massachusetts Installation: Follow this procedure for jurisdictions requiring a vacuum breaker to be installed on the domestic cold water inlet.

• Install the T&P in the run (straight through leg) of tee located at the domestic hot water outlet. Use a long element T&P relief valve (Fig. 3.4).

5. T&P Relief Valve Discharge Piping: T&P relief valve discharge piping must be:

• made of material serviceable for temperatures of 250ºF or greater.

• directed so that hot water flows 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.

T&P relief valve discharge piping must not be:

• excessively long. Using more than 2 elbows or 15 feet of piping can reduce discharge capacity.

• directly connected to a drain. Terminate the discharge piping within 6" from a drain and within 6" of the floor. Refer to local codes.

• plugged, reduced or restricted.

• subject to freezing.

B. DRAIN VALVE

Drain valve and fittings are supplied by others.

1. Standard Installation a. Install a tee connection at the domestic cold water

inlet (Fig. 3.1 and 3.2).

b. Pipe the drain piping with drain valve from the tee

connection to:

i. a suitable place for disposal

ii. terminate within 12" of the floor

2. Commonwealth of Massachusetts Installation a. Use the drain tube assembly supplied in the tank

carton.

b. Thread a 3/4" close nipple onto the Auxiliary

connection and insert an open-end dip tube into the Auxiliary connection on top of water heater. As shown in Fig. 3.3.

c. Install a 3/4" NPT elbow to the Auxiliary

connection, see Fig. 3.4.

d. Pipe the drain piping with drain valve from the

elbow connection to:

To reduce risk of excessive pressures and temperatures in the water heater, install temperature and pressure protective equipment required by local codes, but no less than a combination temperature and pressure relief valve certified 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. This valve must be marked with a maximum working pressure of the water heater.

CAUTION

For proper operation of the T&P and to prevent the T&P from activating due to boiler water temperature, use a T&P relief valve with extended element. Recommended, an 8" minimum length.

NOTICE

Do not install any valve between T&P relief valve and tank connection or on T&P relief valve discharge piping. Do not plug T&P relief valve or discharge piping. Improper placement and piping of T&P relief valve can cause severe personal injury, death or substantial property damage.

WARNING

INSTALLATION - PIPING

Page 9

i. a suitable place for disposal

ii. terminate within 12" of the floor

C. AUTOMATIC AIR VENT

1. Remove plastic shipping cap from 1/2" NPT pipe fitting on top center of water heater.

2. Install 1/2" x 1/8" reducer bushing provided with water heater, using suitable pipe dope or tape.

3. Install automatic air vent provided with water heater, using suitable pipe dope or tape.

4. Unscrew vent cap on air vent one full turn. Leave cap unscrewed one turn for normal venting.

D. THERMAL EXPANSION

If a backflow preventer, check valve or pressure reducing valve is piped on cold water supply piping of water heater, install an expansion tank on cold water supply line to prevent normal thermal expansion from repeatedly forcing open T&P relief valve.

E. WATER HAMMER

Dishwashers, clothes washers and fast-closing positive shut-off valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See device manufacturer’s instructions for application and installation.

F. VACUUM BREAKER

Installing a vacuum breaker Watts N36-M1 or equivalent on the domestic cold water inlet will prevent damage to the inner tank if a negative pressure is developed in the domestic supply line. See manufacturer’s instructions for application and installation of the vacuum breaker.

G. GENERAL PIPING

1. For domestic water piping diagrams, see Figures 3.1 through 3.4.

2. See Figures 3.5 through 3.9 for boiler water piping

3. See Figures 3.10 and 3.11 for multiple water heater domestic piping.

4. See Figure 3.12 for multiple water heater boiler piping.

5. See Table 1.1 for domestic and boiler piping connection sizes.

6. All plumbing must meet or exceed all local, state and national plumbing codes.

7. Use pipe dope or tape suitable for potable water systems.

8. Use isolation valves to isolate system components.

H. DOMESTIC PIPING

1. Union on domestic hot water outlet should be piped at a higher elevation than domestic water drain valve. This will make draining the water heater easier.

2. Install unions for easy removal of water heater. Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe.

3. If copper pipe is used for domestic water connections, first solder pipe to a threaded adapter and then screw adapter into cold water inlet on top of water heater. Inlet contains an internal plastic dip tube which can be damaged by heat from soldering.

Water hammering within the domestic piping system can cause premature failure of the inner tank of the water heater. This type of failure is NOT covered under warranty.

NOTICE

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 domestic water system. Refer to expansion tank manufacturer’s installation instructions for proper sizing.

CAUTION

Table 1.1:

Water Heater Model

Number

Connections - NPT Recirculation Dip Tube Draining Dip Tube

Recommended

Minimum

Boiler Piping

Domestic

Water

Inlet/Outlet

Boiler Water

Supply/

Return

Auxiliary

Connection

Length

(inches)

Diameter

(inches)

Length

(inches)

Diameter

(inches)

Diameter

(inches)

PT-30 3/4 1 3/4 34 3/4 34 3/4 1

PT-40 3/4 1 3/4 43 3/4 43 3/4 1

PT-50 3/4 1-1/4 3/4 25 3/4 52 3/4 1-1/4

PT-60 3/4 1-1/4 3/4 34 3/4 62 3/4 1-1/4

PT-80 1-1/2 1-1/2 1-1/2 25 1-1/2 48 1-1/2 1-1/2

PP-120 1-1/2 2 1-1/2 32 1-1/2 61 1-1/2 2

INSTALLATION - PIPING

Page 10

4. When the water supply pressure is higher than 70 psig, it is recommended to install a pressure reducing valve on cold water supply line to prevent water loss through T&P relief valve.

5. If water heater will replace tankless coil in boiler, disconnect piping to coil. Allow water to drain from coil. Do not plug tankless coil.

I. THERMOSTATIC MIXING VALVE

1. It is recommended to install an optional mixing valve on the domestic hot water outlet.

2. Mixing valve should comply with ASSE 1017.

J. RECIRCULATION PIPING

1. T&P relief valve must be installed in run (straight through leg) of tee located at domestic hot water outlet of water heater.

2. It is recommended that the recirculation dip tube be installed in auxiliary connection using a close nipple assembly as shown Fig. 3.3, page 9. See Table 1.1 page 6 for diameter and length of dip tube.

3. A stainless steel or bronze circulator is recommended.

4. Install automatic mixing valve either at the hot water outlet of water heater or each hot water faucet.

K. MULTIPLE WATER HEATER SYSTEMS

1. Parallel Pipe Recirculation Systems - Manifold recirculation return to all water heaters.

2. Series Piped Systems - Piped return to the leading (cold water inlet) water heater.

3. Install automatic mixing valve either at the hot water outlet of water heater or each hot water faucet.

L. BOILER PIPING

1. If plastic pipe is used for boiler water piping, it must have a maximum oxygen diffusion rate of 0.1 mg/liter-day for boiler and water heater protection.

2. Boiler water (including additives) must be practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products.

If antifreeze is used in boiler system, local codes may require a backflow preventer on cold water supply line. Use antifreeze specifically intended for hydronic heating systems. Inhibited propylene glycol is recommended at a maximum 50/50 mixture.

WARNING

Do not use automotive, ethylene glycol or petroleumbased antifreeze. Do not use any undiluted antifreeze. This can cause severe personal injury, death or substantial property damage.

DANGER

Plugging tankless coil inlet and outlet will result in severe personal injury, death, or substantial property damage.

Do not apply heat to the cold water inlet when making sweat connections to water heater. Sweat tubing to adapter before fitting adapter to cold water inlet of heater. It is imperative that no heat be applied to the cold water inlet, as it contains a non metallic dip tube.

NOTICE

The Peerless®Partner®IDWH must be installed on a closed type hydronic system. Failure to provide such a system will result in premature failure of the outer tank and annulment of warranty.

NOTICE

DANGER

Failure to install automatic mixing valve where recommended will result in severe personal injury or death.

INSTALLATION - PIPING

Page 11

Figure 3.1: Peerless®Partner®Recommended Installation: Domestic Water Piping

Figure 3.2: Peerless®Partner®Recommended Installation: Domestic Water Piping with Recirculation

3. INSTALLATION – PIPING DRAWINGS

1. Shut-off valve

2. Recirculation Circulator

3. Flow Check Valve

4. T&P relief valve

5. Unions

6. Backflow preventer or pressure reducing valve(*)

9. Drain valve

10. Thermal expansion tank (potable)

11. Recirculation dip tube

13. Thermostatic mixing valve (*) (*) Optional devices may be required by local codes.

INSTALLATION - PIPING DRAWINGS

12" min.

Heat Trap

Loop

(Optional)

Heat Trap

(Optional)

12" min.

Loop

Cold Water

12" min.

Heat Trap

Loop

(Optional)

Recirculating

Loop

Heat Trap

(Optional)

12" min.

Loop

Inlet

Cold Water

Inlet

Page 12

Figure 3.3: Domestic Water Drain Tube Assembly: Commonwealth of Massachusetts Requirements

Figure 3.4: Peerless®Partner®Domestic Water Piping: Commonwealth of Massachusetts Requirements

1. Shut-off valves

4. T&P relief valve

5. Unions

6. Backflow preventer or pressure reducing valve (*)

8. Vacuum breaker

9. Drain valve

10. Thermal expansion tank (potable)

11. Dip tube - Draining per Table 1.1

13. Mixing valve (*) (*) Optional devices may be required by local codes.

INSTALLATION - PIPING DRAWINGS

12" min.

Heat Trap

Loop

Heat Trap

Loop

(Optional)

Cold Water

Inlet

Page 13

Figure 3.5: Peerless®Partner®Boiler Piping with 3-Way Valve (Domestic Priority)

INSTALLATION - PIPING DRAWINGS

PIPING LEGEND

Page 14

Figure 3.7: Peerless®Partner®Boiler Piping with Zone Circulators

INSTALLATION - PIPING DRAWINGS

Figure 3.6: Peerless®Partner®Boiler Piping with Zone Valves

Page 15

INSTALLATION - PIPING DRAWINGS

Figure 3.9: Peerless®Partner®Boiler Piping for Peerless®PUREFIRE®Condensing Boilers

Note: Contact PB Heat for optional heat exchanger kit for "Double Wall" applications.

Figure 3.8: Peerless®Partner®Boiler Piping with Plate Heat Exchanger for “Double Wall” Applications

(Refer to the PureFire

Installation, Maintenance, and Operations Manual for alternate piping configurations).

Page 16

INSTALLATION - PIPING DRAWINGS

Figure 3.11: Multiple Peerless®Partner®Water Heater System Domestic Piping - Series

• Recommended for applications in which there is a large water consumption in short period of time.

• A maximum of 3 water heaters may be piped in series.

• Utilize the lead (hot water outlet) Peerless

Partner

tank thermostat to control system temperature.

• Install automatic mixing valve at either the hot water outlet of the water heater system or at each hot water fixture.

• Each tank should be piped with a drain as shown in Figure 3.1

Figure 3.10: Multiple Peerless®Partner®Water Heater System Domestic Piping - Parallel

• Recommended for most applications.

• Any one water heater tank thermostat may be utilized to control system temperature.

• Install automatic mixing valve at either the hot water outlet of the water heater system or at each hot water fixture.

• Each tank should be piped with a drain as shown in Figure 3.1.

Circulator

Recirculated

Water

Automatic

Mixing Valve

Hot Water

Outlet

Cold Water

Inlet

T&P

Relief

Valve

Cold Water

Inlet

Isolation

Valve

Cold Water

Inlet

Circulator

Isolation

Recirculated

Valve

Water

T&P

Relief

Valve

Automatic

Mixing Valve

Hot Water

Outlet

Cold Water

Inlet

Page 17

Figure 3.12: Recommended Multiple Peerless®Partner®Boiler Piping (Reverse Return)

INSTALLATION - PIPING DRAWINGS

Page 18

A. WIRING REQUIREMENTS

1. All wiring must be a minimum of 18 gauge and installed in accordance with:

a. U.S.A. - National Electrical Code and any other

national, state or local code requirements having jurisdiction.

b. Canada - C.S.A. C22.1 Canadian Electrical Code

Part 1 and any other national, provincial and local code requirements having jurisdiction.

2. If original wire supplied with appliance must be replaced, Type 90ºC or its equivalent must be used.

3. Refer to control component instructions packed with boiler for application information.

4. An optional service switch may be installed in water heater electrical circuit. This switch would only shut off the water heater, not the home heating system. Do not shut off water heater if there is a chance of freezing.

5. All electrical contacts shown do not have power applied - off the shelf condition. See Figures 5.1 through 5.9.

B. CIRCULATORS

Priority relay must be sized for total amp draw of all circulators.

C. ZONE VALVES

Transformer must be sized for maximum load of all zone valves.

D. SNAP SET CONNECTION

1. For easy wiring between water heater thermostat and boiler controls see Installation Wiring section Figures

5.1 through 5.9.

2. Make sure snap set is firmly snapped together after wiring.

Electrical shock hazard can cause severe personal injury, death or substantial property damage. Disconnect power before installing and/or servicing.

WARNING

4. INSTALLATION – WIRING

INSTALLATION - WIRING

Page 19

5. INSTALLATION – WIRING DRAWINGS

INSTALLATION – WIRING DRAWINGS

Figure 5.2: Typical 3-Wire Zone Valve Zoning, With

Domestic Priority

Figure 5.1: Typical 4-Wire Zone Valve Zoning, With

Domestic Priority

Page 20

INSTALLATION – WIRING DRAWINGS

Figure 5.4: Typical 3-Wire Zone Valve Zoning,

Without Domestic Priority

Figure 5.3: Typical 4-Wire Zone Valve Zoning,

Without Domestic Priority

V.A.C.

Page 21

INSTALLATION – WIRING DRAWINGS

Figure 5.5: Typical Circulator Zoning With

Domestic Priority

Figure 5.6: Typical Circulator Zoning Without

Domestic Priority

Page 22

INSTALLATION – WIRING DRAWINGS

Figure 5.7: Circulator Zoning Without Domestic Priority, Series MI

Figure 5.8: Circulator Zoning Without Domestic Priority, Series WBV/WV, WV-DV, EC, SC

Page 23

INSTALLATION – WIRING DRAWINGS

Figure 5.9: Priority Zoning Circulator Wiring

Note: Maximum of 4 total circulator zone

when wiring 1 zone for priority.

Page 24

6. WATER HEATER START-UP

A. FILLING THE INNER (DOMESTIC WATER)

TANK

1. Close domestic water drain valve.

2. Open domestic water isolation valves for water heater.

3. Vent air from inner (domestic water) tank by opening nearest hot water faucet. Fill domestic water tank completely by allowing water to run until there is a constant flow of water.

4. Close hot water faucet.

B. FILLING THE OUTER (BOILER WATER)

TANK

1. Close boiler water drain valve at boiler water outlet of water heater.

2. Open water heater’s boiler water isolation valves.

3. Allow air to escape from outer (boiler water) tank by opening vent cap A on automatic air vent, located on top of water heater. See Figure 6.1.

4. Follow instructions furnished with boiler to fill with water.

5. When tank is full, air will stop escaping, and the automatic air vent will close. If air vent does not seat properly (water leaks out), remove cap A. Briefly push in valve B and release it to clean valve seat. Screw cap A on completely, then unscrew one turn. See Figure 6.1.

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

– Install an automatic mixing valve at water

Never use water heater unless inner and outer tanks are completely filled with water. Inner tank must be completely filled and pressurized before pressurizing outer tank.

CAUTION

Never use water heater unless inner and outer tanks are completely filled with water. Inner tank must be completely filled and pressurized before pressurizing outer tank.

CAUTION

For proper operation of the water heater, be sure the top cap is tightened at all times.

NOTICE

Do not use automotive, ethylene glycol or petroleumbased antifreeze. Do not use any undiluted antifreeze. This can cause severe personal injury, death or substantial property damage.

WARNING

Figure 6.1: Automatic Air Vent

WATER HEATER START-UP

DANGER

HOT WATER CAN SCALD!

• Water temperatures over 125°F can cause severe burns instantly, or death from scalds.

• Feel water before bathing or showering.

• Consumer Product Safety Commission and some states recommend temperatures settings of 130ºF or less. Setting thermostat higher than 130ºF will increase risk of scald injury and cause severe personal injury or death.

• Water heated to a temperature suitable for clothes washing, dish washing and other sanitizing needs will scald and cause permanent injury.

• Children and elderly, infirm, or physically handicapped persons are more likely to be injured by hot water. Never leave them unattended in or near a bathtub. If anyone using hot water in the building fits this description, or if state laws or local codes require certain water temperatures at hot water faucets, take special precautions.

Page 25

C. GENERAL NOTES

• Household water usage patterns will affect water temperature at any faucet or shower. Occasionally check temperature at each point of use, then adjust thermostat accordingly. Always recheck temperature after adjusting thermostat.

• When hot water is used in repeated small quantities, a “stacking” effect can develop in the water heater. The upper layer of water in tank can be hotter than lower layer.

• Lowering the thermostat setting or installing automatic mixing valves as indicated in these instructions will reduce water temperature levels. Consult your installer or service technician.

D. ADJUSTING THE WATER HEATER

THERMOSTAT

Water heater thermostat is factory set to its lowest temperature.This may or may not be suitable for your needs.

Turn thermostat knob clockwise  to increase water temperature.

Turn thermostat knob counter-clockwise  to decrease water temperature.

• Measure water temperature at a hot water faucet immediately after first heating cycle. Further temperature adjustment may be necessary as water heating system is used. Recheck water temperature at faucet after adjustment.

• When adjusting thermostat, be sure boiler limit control is set a minimum of 20ºF higher.

WATER HEATER START-UP

At no time should boiler limit control be set above 210°F. This can cause severe personal injury, death or substantial property damage if ignored.

WARNING

Studies have indicated that dangerous bacteria, including legionella, pneumophila, can form in the potable water distribution system if certain minimum water temperatures are not maintained. Contact your local health department for more information.

WARNING

Figure 6.2: Peerless®Partner®Knob

DANGER

HOT WATER CAN SCALD! – Install an automatic mixing valve at water heater or

at each hot water faucet, bath and shower outlet. Selection and installation must comply with valve manufacturer’s recommendation and instructions.

– Use the lowest practical temperature setting.

– Measure water temperature at hot water faucet after

any adjustment. You must follow “Adjusting the Water Heater Thermostat” procedures.

Page 26

7. WATER HEATER MAINTENANCE

WATER HEATER MAINTENANCE

A. MAINTENANCE SCHEDULE

Annual service by qualified service technician should include the following:

1. Any procedure required by local codes.

2. Check air vent operation.

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

4. Manually operate T&P relief valve at least once a year. This will release some hot water.

5. Move operating lever to open position for a few seconds and then move it back, allowing it to snap closed. After T&P relief valve is operated, if it continues to release water, close cold water inlet to water heater immediately. Follow draining instructions, and replace T&P relief valve. If T&P relief valve weeps periodically, it may be due to thermal expansion see Thermal Expansion, page 5. Do not plug T&P relief valve or discharge piping.

6. Follow instructions on circulator to oil it, if required.

7. Check mixing valve, valves, pipes and fittings for leaks.

8. Check function of field-installed controls and valves. See component manufacturer’s instructions.

9. Review homeowner’s maintenance responsibilities and their frequencies, including any not listed in the following section.

Homeowner monthly maintenance to include:

• Check air vent operation.

Automatic air vent - remove cap. Briefly push in valve and release it to clean valve seat. Screw cap on completely, then unscrew one full turn. If air vent does not operate, call qualified service technician.

• Visually check valves, pipes and fittings for leaks. Call qualified service technician to repair leaks.

B. FILLING WATER HEATER

See “Filling the Inner (Domestic Water) Tank and “Filling the Outer (Boiler Water) Tank” on in Section 6.A and 6.B.

C. DRAINING WATER HEATER

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

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

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

If antifreeze is used in boiler water, check concentration. Boiler water (including additives) must be practically nontoxic, having toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products. A maximum 50/50 mixture of inhibited propylene glycol is recommended. Follow antifreeze manufacturer’s instruction.

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

WARNING

DANGER

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

Close boiler water isolation valves and relieve system pressure to below 15 psig in outer tank before draining inner tank to prevent damage to inner tank.

WARNING

Do not use automotive, ethylene glycol or petroleumbased antifreeze. Do not use any undiluted antifreeze. This can cause severe personal injury, death or substantial property damage.

WARNING

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.

WARNING

Page 27

D. DRAINING INNER (DOMESTIC WATER)

TANK

(See Domestic Piping Fig. 3.1)

1. Disconnect snap set wiring connection at water heater.

a. If outer (boiler water) tank pressure is greater than

15 psig, relieve boiler pressure and close isolation valves before proceeding.

2. Close system supply isolation valve.

3. Connect a hose to domestic water drain valve at cold water inlet. Hose should extend to drain at floor level to allow siphoning of domestic water tank.

4. Open hot water faucet at highest point above heater.

5. Open domestic water drain valve to start siphoning.

6. When draining is complete, close hot water faucet and domestic water drain valve.

E. DRAINING OUTER (BOILER WATER) TANK

1. Disconnect snap set wiring connection at water.

2. Close boiler water isolation valves between boiler and water heater.

3. Connect hose to boiler water drain valve at water heater. Open and drain water to a safe place.

4. To speed draining procedure, loosen air vent on top of tank.

5. When draining is complete, close drain valve and retighten air vent.

WATER HEATER MAINTENANCE

Page 28

8. TROUBLESHOOTING

TROUBLESHOOTING

Table 8.1: Troubleshooting

Problem Cause Solution

No hot water at faucet.

Boiler does not operate

Refer to boiler installation instructions

Check main service switch

Check fused disconnect

Circulator does not operate

Check power supply

Check circulator switching relay

Improper tank thermostats setting or calibration Turn tank thermostat to higher setting

Zone valve does not open (if used) Check power supply

Electrical problem (relay, wiring, fuse, etc.)

Check fuse and replace

Check circuit breaker and reset (if applicable)

Check power supply

Air trapped in boiler supply to tank Purge piping

Insufficient hot water.

Tank thermostat Adjust thermostat to higher setting

Undersized boiler with no priority to domestic hot water

Rewire for priority

Peak use of hot water is greater than tank storage capacity

Determine peak usage and compare to tank volume

Undersized circulator Check recommended circulator size in Table 11.1 and 11.2

Faulty tank thermostat Replace thermostat

Water at faucet too hot.

Tank thermostat set too high Lower thermostat setting

Improper system plumbing Compare plumbing to Section 3

Improper system wiring Compare wiring to Section 4 Tank thermostat faulty Replace thermostat

Excessive boiler cycling per day during summer.

Large demand Reduce demand or consider larger tank

Faulty tank thermostat Replace thermostat

Boiler high limit set too low Increase boiler high limit setting

Page 29

9. REPAIR PARTS

REPA IR PART S

Table 9.1: Repair Parts

Description Models

Stock

Code

1 Air Vent, Automatic All 51329

Thermostat - 160°F Residential All 51330

Thermostat - 194°F Commercial All 51331

3 Bottom Cap

PT-30, 40, 50, 60 51332

PT-80 51333

PT-120 51334

4 To p

PT-30, 40, 50, 60 51335

PT-80 51336

PT-120 51337

5 Thermostat Drywell

PT-30 51338 PT-40

51339

PT-50

51340

PT-60, PT-80

51341

PT-120

51342

Dip Tube

PT-30

51343

PT-40 51344 PT-50 51345 PT-60 51346 PT-80 51347

PT-120 51348

Page 30

REPA IR PART S

Figure 9.1: Peerless®Partner® Tank Components

Figure 9.2: Thermostat Cover Plate Assembly

Page 31

10.

WATER HEATER DIMENSIONS & RATINGS

Figure 10.1: Top View

Figure 10.2: Rear View

Table 10.1

PEERLESS®PARTNER®DIMENSIONS & RATINGS

Water

Heater

Model

Number

Capacity (gallons)

Heating Surface

(sq. ft.)

Boiler

Head

Loss at

Min.

Flow (Ft. of Water)

Piping Connections

(NPT)

Dimensions (inches)

Thermo-

stat

Drywell

Length

(inches)

Empty

Wei gh t

(lbs.)

Domes-

tic Boiler

Domes-

tic Boiler Aux. A B C D E F

PT-30 28 5 13 .75

³⁄₄

38 9 30 22 14 6 25 115

PT-40 39 6 16 1.0

³⁄₄

46 9 38 22 14 6 29 135

PT-50 46 8 20 1.25

³⁄₄

1¹⁄₄

³⁄₄

57 9 49 22 14 6 37 165

PT-60 56 8 24 1.50

³⁄₄

1¹⁄₄

³⁄₄

66 9 58 22 14 6 47 190

PT-80 70 14 29 2.0

1¹⁄₂ 1¹⁄₂ 1¹⁄₂

61 10

50¹⁄₂

10¹⁄₂ 10¹⁄₂

47 271

PT-120 119 43 42 2.50

1¹⁄₂

72 10 64 32

10¹⁄₂

5 51 479

Page 32

Table 11.2

Table 11.1

11. PERFORMANCE RATINGS

Water Heater

Model Number

Boiler Heating Capacity MBH

Peak Flow

Gallon/10 Minute

1st Hour Flow

Gallon/Hour

Continuous Flow

Gallon/Hour

Circulator

Minimum GPM

PT-30 PT-40 PT-50 PT-60 PT-80

PT-120

102 131 164 316 351 492

54 69

87 142 164 246

210 271 339 628 704

1003

188 242 302 583 648 907

10 13 16 32 35 49

Conditions: 50°F Domestic Cold Water Inlet Temperature

115°F Domestic Hot Water Outlet Temperature

200°F Boiler Water Supply Temperature

Water Heater

Model Number

Boiler Heating Capacity MBH

Peak Flow

Gallon/10 Minute

1st Hour Flow

Gallon/Hour

Continuous Flow

Gallon/Hour

Circulator

Minimum GPM

PT-30 PT-40 PT-50 PT-60 PT-80

PT-120

87 112 140 270 300 420

42 54

68 105 123 189

138 178 224 405 456 655

116 149 187 360 400 560

9 11 14 27 30 42

Conditions: 50°F Domestic Cold Water Inlet Temperature

140°F Domestic Hot Water Outlet Temperature 200°F Boiler Water Supply Temperature

Table 11.3

Water Heater

Model Number

Boiler Heating

Capacity MBH

Peak Flow

Gallon/10 Minute

1st Hour Flow

Gallon/Hour

Continuous Flow

Gallon/Hour

Circulator

Minimum GPM

PT-30 PT-40 PT-50 PT-60 PT-80

PT-120

86 107 206 229 321

37 48 61

91 107 167

111 143 180 320 362 523

89 114 143 275 306 428

9 11 21 23 32

Conditions: 50°F Domestic Cold Water Inlet Temperature

140°F Domestic Hot Water Outlet Temperature 180°F Boiler Water Supply Temperature

Table 11.4

Water Heater

Model Number

Boiler Heating

Capacity MBH

Peak Flow

Gallon/10 Minute

1st Hour Flow

Gallon/Hour

Continuous Flow

Gallon/Hour

Circulator

Minimum GPM

PT-30 PT-40 PT-50 PT-60 PT-80

PT-120

82 106 132 255 284 397

48 61

78 123 143 217

174 224 281 516 579 828

152 195 244 471 523 733

8 11 13 26 28 40

Conditions: 50°F Domestic Cold Water Inlet Temperature

115°F Domestic Hot Water Outlet Temperature 180°F Boiler Water Supply Temperature

PERFORMANCE RATINGS

Page 33

PERFORMANCE RATINGS

Table 11.5 First Hour Ratings for Reduced Boiler Output (Gallons)

Boiler

Output

(MBH)

PT-30 PT-40 PT-50 PT-60 PT-80 PT-120

140°F 115°F 140°F 115°F 140°F 115°F 140°F 115°F 140°F 115°F 140°F 115°F

40 76 96 82 103 90 111 98 119 109 130 149 169

50 89 115 95 121 103 129 111 137 123 148 162 188

60 102 133 109 140 117 148 125 156 136 167 175 206

70 116 152 122 158 130 166 138 174 149 185 189 224

80 129 170 135 176 143 184 151 192 163 204 202 243

90 --- 189 149 195 157 203 165 211 176 222 215 261

100 --- 207 162 213 170 221 178 229 189 241 229 280

120 --- --- --- 250 197 258 205 266 216 278 255 317

140 --- --- --- --- 223 295 231 303 243 314 282 354

160 --- --- --- --- --- 332 258 340 269 351 309 391

180 --- --- --- --- --- --- 285 377 296 388 335 428

200 --- --- --- --- --- --- 311 414 323 425 362 464

220 --- --- --- --- --- --- 338 451 349 462 389 501

240 --- --- --- --- --- --- 365 488 376 499 415 538

260 --- --- --- --- --- --- 391 525 403 536 442 575

280 --- --- --- --- --- --- --- 562 429 573 469 612

300 --- --- --- --- --- --- --- 599 456 610 495 649

340 --- --- --- --- --- --- --- --- --- 684 549 723

380 --- --- --- --- --- --- --- --- --- --- 602 797

420 --- --- --- --- --- --- --- --- --- --- 655 871

460 --- --- --- --- --- --- --- --- --- --- --- 944

Note: shaded values are recommended only for PureFire®and Pinnacle®boilers due to potential for condensation.

Page 34

NOTES

Page 35

Partner

Water Heater

Peerless

Indirect-Fired

Installation, Operation & Maintenance Manual

TO THE INSTALLER:

This manual is the property of the owner and must be affixed near the water heater for future reference.

TO THE OWNER:

This water heater should be inspected annually by a Qualified Service Agency.

PB HEAT, LLC

131 S. CHURCH STREET • BALLY, PA 19503

PT-30 PT-40 PT-50 PT-60 PT-80 PT-120

X8167 R0 (12/11-2M)