PEERLESS PT-30, PT-40, PT-60, PT-80, PT-50 Installation, Operation & Maintenance Manual
...
Partner
®
Water Heater
PT-30 PT-40 PT-50 PT-60 PT-80 PT-120
Peerless
®
Indirect-Fired
Installation,
Operation &
Maintenance
Manual
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
TABLE OF CONTENTS
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
1
USING THIS MANUAL
2
PRODUCT SAFETY & INFORMATION
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.
or
– 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
3
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
4
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.
5
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
6
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).
or
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
or
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
7
i. a suitable place for disposal
or
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
8
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
9
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
5
12" min.
Heat Trap
Loop
(Optional)
1
9
Heat Trap
(Optional)
1
5
12" min.
Loop
9
10
6
10
Cold Water
1
1
6
12" min.
Heat Trap
Loop
(Optional)
13
H
M
1
Recirculating
Loop
C
1
Heat Trap
(Optional)
5
2
12" min.
Loop
4
3
4
5
11
Inlet
Cold Water
Inlet
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