PEERLESS Partner PP-30-LB Instruction manual

Partner®
Water Heater
Peerless®
Indirect-Fired
Installation,
Operation &
Maintenance
Manual

1
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 = __________
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.
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.
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
!
!
Product Selection

1. First hour rating based on heating water from 50°F to 140°/115°F with 180°F boiler water temperature. Gas- and oil-fired
and electric water heater first hour ratings based on DOE test procedure using 90°F temperature rise (55°F to 145°F).
2. Net I=B=R Output, Water
3. Useable hot water based on recent completion of recovery period, but no additional boiler input after draw begins.
Table 1: Peerless Partner Ratings
2
d. Boiler. PP-80, PP-120, PP-80-DW, and PP-120-DW require full boiler output listed in Table 1. If boiler is a
condensing boiler, such as Peerless®Pinnacle®, the above Peerless®Partner®models can be used with
reduced boiler output. If boiler output is less than shown in Table 1 reduce first hour rating as shown in
Table 2. Increase boiler size only if first hour rating does not meet estimated peak hour usage.
If a boiler with listed output is not needed for space heating, an alternative to a PP-80/120 would be
a PP-40 or PP-60 piped in series with an unfired storage tank (i.e. electric water heater without heating
elements energized).
If Peerless Partner is to be used with Peerless Boilers Series 63 or Series 64 steam boiler, refer to Series
63/64 Installation, Operation and Maintenance Manual for special installation and operation instructions.
PB Heat, LLC cannot recommend the use of other steam boilers with Peerless Partner at this time. Other
than Series 63 and Series 64 steam boilers, Peerless Partner should only be used with water boilers.
Contact PB Heat, LLC for additional information.
e. 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.
Model
No.
First Hour Rating1[gallons] Minimum Boiler Output2to Achieve
First Hour Rating [Btu per hour]
Useable Hot Water
[U.S. Gallons]3
Heat Exchanger
Surface Area [ft2]140°F 115°F
PP-30-LB 169 234 114,000 22 15
PP-40 212 292 141,000 28 20
PP-60 266 370 174,000 46 20
PP-80 330 440 212,000 64 34
PP-120 423 564 269,000 94 34
PP-40-DW 70 108 107,000 28 20
PP-60-DW 90 144 176,000 46 20
PP-80-DW 138 215 208,000 64 20
PP-120-DW 210 326 231,000 94 20

Pre-Installation Considerations
3
PP-40 16 14 12 10 9 8 7 6 5.5 5 4.2 3.7
PP-60 ** ** 30 24 20 17 10.3 9.5 8.2 7.8 7.1 6.1
PP-80 ** ** ** ** ** ** 14 13 12 11.1 10.5 8.5
PP-120 ** ** ** ** ** ** 20 18 16 15 14 12.5
Model
No. 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5
Domestic Water Flow Rate [gpm]
Table 3: First Draw at 140°F1,2 (in Minutes)
**Unlimited hot water available at specified flow rate.
1. Based on cold start boiler with output listed in Table 1.
2. For minutes of domestic water flow at 115°F, multiply by 1.56.
Table 2: First Hour Ratings for Reduced Boiler Output
1. 180°F Boiler Water
2. 200°F Boiler Water
3. Due to condensation in boiler, reduced output not recommended for PP-80, PP-120, PP-80-DW, and PP-120-DW.
Condensing boilers, such as Peerless Pinnacle, can be used for reduced output.
1. Read these instructions completely before starting installation.
2. FOR YOUR SAFETY: Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this
or any other appliance. Controls on this appliance could ignite vapors causing an explosion.
3. Install in accordance with the requirements of the authority having jurisdiction. In the absence of such
requirements, appliance must be wired in accordance with the
National Electrical Code, ANSI/NFPA 70 .
This product complies with 1990 N.S.P.C. provided: (1) the boiler water, including additives, is practically non-
toxic, having a toxicity rating or class of 1, as listed in Clinical Toxicology of Commercial Products, 5th edition; and
(2) the boiler water pressure is limited to a maximum of 30 psig by an approved safety or safety relief valve.
Boiler Output
[Btu per hour}
PP-30-LB PP-401PP-601PP-802,3 PP-1202,3
140°F115°F140°F115°F140°F115°F140°F115°F140°F115°F
40,000 60 84 68 94 – – – – – –
60,000 92 128 99 138 – – – – – –
80,000 115 160 130 180 – – – – – –
100,000 153 211 152 210 160 221 216 297 – –
120,000 – – 182 251 176 244 223 305 – –
140,000 – – – – 181 251 230 314 216 333
160,000 – – – – 206 309 269 367 251 384
180,000 – – – – – – 311 424 290 444
200,000 – – – – – – 359 489 335 457
220,000 ––––––––345 470
240,000 ––––––––399 543
260,000 ––––––––460 627

4
4. Peerless Partner(s) may be located adjacent to boiler to reduce piping heat loss or central to points of use to
reduce response time to fixtures.
a. Install indoors in an area not exposed to freezing temperatures. Do not install outdoors.
b. Position with adequate clearance for service and maintenance. Provide access to thermostat, temperature
and pressure relief valve, and drain valve.
c. Protect surrounding area and lower floors from damage due to leakage from temperature and pressure
relief valve, drain valve, boiler or domestic water piping, and tank. Locate water heater near a floor drain or
in a drain pan suitable for the capacity of the water heater.
d. Install on level surface. Water heater must be kept in vertical position.
5. Suggested equipment list. See PIPING for additional information.
a. Water Heater Thermostat: Provided.
b. Temperature and Pressure Relief Valve: Provided.
c. Brass Drain Valve: 1 per water heater.
d. Brass Tee’s: 2 per water heater.
e. Heat Exchanger to Boiler Piping: 1 inch nominal copper tubing and fittings. Circulator and flow control
valve, or zone valve.
1. General
a. All plumbing must be in accordance with
the requirements of the authority having
jurisdiction.
b. Use both thread tape and pipe dope on all
mechanical connections.
c. Zone valve (if used) and circulator must be
sized to provide minimum flow rate speci-
fied in Table 4. Use 1 inch nominal copper
tubing between boiler and Peerless Partner
heat exchanger. See Table 5 and Table 6 for
sizing. Point of emphasis: using a zone
valve without a full bore may cause high
pressure drop which will adversely affect
performance. Use extreme care when
selecting zone valve.
All piping must be adequately supported.
Allow for thermal expansion.
d. High temperatures will damage plastic jack-
et. Use heat shield when soldering piping
near tank. Table 6: Friction Loss Allowance for Copper Fittings
[feet of straight tubing]
90° Elbow 1 4
45° Elbow 1 2
Tee, Run 1/21/2
Tee, Branch 3 5
90° Bend 2 –
180° Bend 2 –
Gate Valve –1
Fitting Wrought Cast
Piping
Table 5: Friction Loss per 100 Feet of Tubing [feet]
Type K 3.6 4.8 9.3
Type L 3.1 4.1 8.1
Type M 2.7 3.6 7.0
Tubing Type
Flow Rate [gpm]
6 7 10
Table 4: Flow Specifications
Model No. Recommended
Flow Rate
Heat Exchanger
Pressure Drop
Domestic Water
Connection Sizes
PP-30-LB 8 gpm 6.0 ft. 3/4 NPT
PP-40 10 gpm 7.9 ft. 3/4 NPT
PP-60 10 gpm 7.9 ft. 1 NPT
PP-80 12 gpm 9.1 ft. 1-1/2 NPT
PP-120 14 gpm 11.3 ft. 1-1/2 NPT
PP-40-DW 6 gpm 8.2 ft. 3/4 NPT
PP-60-DW 7 gpm 12.8 ft. 1 NPT
PP-80-DW 10 gpm 13.6 ft. 1-1/2 NPT
PP-120-DW 12 gpm 15.9 ft. 1-1/2 NPT

Figure 3: Hot Water Outlet
2. Domestic Water
a. Cold Water In. Install brass tee and drain valve
(not provided). Install shutoff valve between
water supply and cold water inlet for ease of
service. See Figure 1.
For systems using a back flow preventer or no
return valve, install a thermal expansion tank
between cold water supply and valve to offset
expansion/pressure increase as water is heated.
See Figure 2.
b. Standard Domestic Hot Water Out. Install
brass tee and temperature and pressure relief
valve. Do not place any valves between the
temperature and pressure relief valve and the
tank. See Figure 3.
Run temperature and pressure relief valve dis-
charge piping to a suitable place to avoid dam-
age to building or injury to occupants. Do not
install reducing fittings or other restrictions.
Discharge piping must allow complete drainage
of both the temperature and pressure relief valve
and piping.
A heat trap will improve energy efficiency by
reducing piping heat loss.
c. Domestic Hot Water Out with Mixing Valve.
See Figure 4.
3. Boiler. Install Peerless Partner as a separate space
heating zone. Place boiler circulator(s) in boiler
supply piping.
For boiler with tankless heater, disconnect domestic
water piping and limit control (where used). Plug
limit tapping. Do not plug domestic water tappings.
4. Multiple Water Heaters installed as single unit.
Install boiler water piping and domestic piping in
parallel reverse return configuration. See Figure 5.
5. Peerless Partner with unfired storage tank. See
Figure 6.
Figure 1: Water Inlet
Figure 2: Thermal Expansion Tank
5
Figure 4: Mixing Valve

6
Figure 5: Installation of Multiple Water Heaters as Single Unit
Figure 6: Unfired Storage Tank
1. The Peerless Partner must be electrically grounded in accordance with local codes. In the absence of local
codes follow the National Electrical Code , ANSI/NFPA 70.
2. Install thermostat provided with Peerless Partner. Insert bulb into immersion well. Secure to well by tightening
screws on case.
3. Wire Peerless Partner thermostat to boiler. Provide disconnect switch between thermostat and control system
to allow for vacation shutdown and/or service shutdown.
Zoning with zone valves assumes end switch is isolated – zone valve actuator powered by separate
transformer. Do not use boiler transformer to operate zone valves.
a. MI/MIH. For zoning with zone valves or three-way valve, connect zone valve end switch to limit terminals T
and TV. For zoning with circulators, refer to Figure 7.
b. DE/PSC. Provide zone control as shown in boiler’s installation instructions.
d. WBV/EC/SC. Water less tankless heater. See Figure 8.
Electrical

7
Figure 7: Wiring Diagram – MI/MIH Figure 8: Wiring Diagram – WBV/WV, WV-DV, EC, PRO
and SC less Tankless
1. General
a. Open hot water faucet when filling or draining Peerless Partner.
b. The Peerless Partner thermostat has three markings: Warm (120°F), Normal (140°F), and Hot (160°F).
The thermostat is adjusted to its lowest temperature position when shipped from the factory.
2. Fill tank and domestic water piping.
3. Adjust Peerless Partner thermostat to 119°F, or in accordance with authority having jurisdiction. Adjust
mixing valve (if used) to desired temperature.
4. Follow manufacturer’s instructions to start-up boiler. Set boiler limit at least 20°F above Peerless Partner
thermostat setting. For boiler limit with low limit, set temperature to lowest setting. For boiler limits with
adjustable differential, set differential to 10-15°F range.
5. Operate boiler until Peerless Partner thermostat satisfied. Measure domestic water temperature at hot
water faucet. See Paragraph 3 above.
6. Draw hot water and allow Peerless Partner to operate through several recovery cycles to verify proper
operation.
Start-up
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.
DANGER
!

8
1. General Housekeeping (continuous). Keep area clear of gasoline or other flammable vapors or liquids.
Controls on this appliance could ignite vapors causing an explosion.
2. Clean Inside of Tank (monthly).
a. Mark temperature setting on Peerless Partner thermostat. Set thermostat to lowest setting.
b. Close cold water inlet shutoff valve. Open a hot water faucet.
c. Open drain valve. Allow water to flow until free of sediment. Close drain valve.
d. Open cold water inlet shutoff valve. Close hot water faucet after flow established.
e. Set Peerless Partner thermostat to operating set point.
3. Check temperature and pressure relief valve. Follow manufacturer’s instructions.
4. Maintain boiler per manufacturer’s instructions.
Maintenance
1. No Hot Water
a. No power to boiler and control system.
* Check fuse or circuit breaker.
* Check disconnect switch.
* Check wiring.
b. Zone Valve is not open.
* Check wiring.
* Repair or replace zone valve.
c. Circulator is not operating.
* Check wiring.
* Check circulator switching relay.
* Repair or replace circulator.
d. Peerless Partner thermostat not calling for heat.
* Check wiring.
* Replace thermostat.
e. Hot water from boiler not getting to Peerless Partner.
* Air trapped in boiler piping, preventing water circulation. Purge piping.
* Check boiler for proper operation.
* Check wiring.
2. Inadequate Hot Water
a. Check operation of Peerless Partner.
i. Obtain container with known volume (in gallons) and stopwatch.
ii. Open hot water faucet until boiler starts recovery period. Close faucet.
iii. Allow boiler to operate until water heater fully recovers. Set thermostat disconnect switch to OFF
position.
iv. Open hot water faucet until water is hot. Begin filling container. Use stopwatch to measure time to fill
container.
Troubleshooting
Container Volume (gallons) seconds
F l o w R a t e ( g p m ) = ---------------------------------------------------------------------------------- x 6 0 -----------------------------
Time to Fill Container (seconds) minute

9
Example No.1: A Peerless Partner PP-40 with a Peerless MI-03 gas boiler (DOE Heating Capacity of 58 Mbh).
The desired water temperature is 115°F. Cold water temperature is 55°F.
4. Water Temperature Too Hot
a. Peerless Partner thermostat set too high. Adjust to lower setting.
b. System piping and/or controls.
* Peerless Partner thermostat continues to call for heat after reaching setpoint. Replace thermostat.
* Check system piping and flow control valve. Verify space heating call for heat does not cause flow through Peerless
Partner heat exchanger.
c. Mixing Valve (if used). Verify proper operation per manufacturer’s instructions.
5. Leaking Temperature and Pressure Relief Valve
a. Water expands when heated.
* Install thermal expansion tank on cold water inlet.
* Reduce Peerless Partner thermostat setting.
b. Water temperature too high. See Paragraph 4 above.
c. Water pressure is too high. Install pressure reducing valve on cold water inlet.
d. Valve seat has deteriorated or has sediment build-up. Replace temperature and pressure relief valve.
Example No. 2: A Peerless Partner PP-120 with a Peerless LC-04 (Gross I=B=R Output of 547 Mbh). The
desired water temperature is 150°F. Cold water temperature is 50°F.
Btu
Tank Capacity [gallons] x Temperature Rise [°F] x 8.33 -----------------------------
(gallons)(°F) minutes
R e c o v e r y T i m e [ M i n u t e s ] = ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- x 6 0 -------------------------
Btu hr
Boiler Output -------------- *
hr
Btu
(37 gallons) x (115°F-55°F) x 8.33 -----------------------------
(gallons)(°F) minutes
R e c o v e r y t i m e = --------------------------------------------------------------------------------------------------------------------------------------------- x 6 0 ------------------------- = 1 9 . 1 m i n u t e s
Btu hr
58,000 --------------
hr
Btu
(119 gallons) x (150°F-50°F) x 8.33 -----------------------------
(gallons)(°F) minutes
R e c o v e r y t i m e = ----------------------------------------------------------------------------------------------------------------------------------------- x 6 0 ------------------------- = 1 0 . 9 m i n u t e s
Btu hr
547,000 --------------
hr
v. Water temperature will remain constant within ±5°F until storage is exhausted. Continue to fill container
until temperature drops 10°F.
vi. Compare total volume of water collected to Usable Hot Water in Table 1. If within 5 gallons the Peerless
Partner is operating properly. Check PRODUCT SELECTION for proper model usage.
vii. Compare calculated flow rate with first draw usage available per Table 3. If actual flow rate is greater
than first draw usage available, consider use of flow restricting fixtures or mixing valve.
b. Inadequate boiler water flow. Check circulator sizing per PIPING.
c. Boiler is undersized.
3. Slow Recovery.
See 2(b)(c) above. Approximate cold start recovery period (* use Minimum Boiler Output from Table 1 or
Boiler Rated Output, whichever is smaller):

10
Thermostat: Honeywell L4080B1295 (Operating range = 120°F to 160°F, 15° fixed differential) Stock Code 51294
Temperature and Pressure Relief Valve: PP-40: Watts 100XL-8 (100 Mbh, 8” element)
PP-60/80/120: Watts 40XL-8 (200 Mbh, 8” element)
Well: 1/2” NPT Stainless Steel Long Shank with 3/4” NPT Bushing (Stock Code PMW3SENP)
Dimensions
Repair Parts
Table 7: Dimensions and Specifications
Figure 9: Cutaway View
Model
No.
Dimensions [inches] Pressures
[psig] Tank
Capacity
[U.S.
Gallons]
Diameter Height Floor to
‘Boiler In’
Floor to
‘Boiler Out’
Floor to
‘Cold - Drain’
Floor to
‘Hot - T&P’ Test Working
PP-30-LB 23¼ 28½ 94½ 4½ 22 300 150 30
PP-40 19¼ 52½ 94½ 4½ 46 300 150 37
PP-60 23¼ 52½ 94½ 4½ 46 300 150 57
PP-80 23¼ 72 29 5½ 5½ 64 300 150 77
PP-120 27 73½ 30¼ 7¼ 7¼ 66 300 150 119
PP-40-DW 19¼ 52½ 94½ 4½ 46 300 150 37
PP-60-DW 23¼ 52½ 94½ 4½ 46 300 150 57
PP-80-DW 23¼ 72 29 5½ 5½ 64 300 150 77
PP-120-DW 27 73½ 30¼ 7¼ 7¼ 66 300 150 119

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.
X8033 R10 (9/08-3M)
Printed in U.S.A.
E113265
PB HEAT, LLC
131 S. CHURCH STREET • BALLY, PA 19503
©2008