Weil-McLain Aqua Plus Series 2 Indirect Fired Water Heater Manual

Weil-McLain Aqua Plus Series 2 Indirect Fired Water Heater Manual
®
®
S i 2
Series
Indirect-Fired Water Heaters
Product Manual
• Installation • Maintenance
• Startup
• Parts
®
User — Read important user safety information found on page 3, page 27 and page 28. Installation and service should only be
performed by a qualified service technician. Retain this manual for future reference.
This manual must only be used by a qualified heating installer/service technician. BEFORE installing, read all instructions
in this manual and all other information shipped with the water heater. Perform steps in the order given. Failure to comply
could result in severe personal injury, death or substantial property damage.
Part number 633-600-020/0918
®
INDIRECT-FIRED WATER HEATERS
AQUA PLUS Series 2
— Product Manual
Contents
Please read before proceeding
When servicing water heater
Operating restrictions . . . .
Boiler water restrictions . . .
Location . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
3
Wiring — zoning with circulators
23
.3
.3
.3
.3
Wiring — zoning with zone valves
23
Mounting and wiring the Control - New Installations 24
Pre-installation
4
Codes . . . . . . . . . . . . . . . . . .
Code restrictions . . . . . . . . . . . .
Water heater placement . . . . . . . .
Install levelling legs . . . . . . . . . .
Domestic water piping requirements.
Water heater operating restrictions. .
Boiler water restrictions . . . . . . . .
Hot Water Can Scald! . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Domestic water piping
.4
.4
.4
.4
.5
.5
.5
.5
6
Piping overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Recirculation
Setting the Control
25
Water heater filling and start-up
Boiler water restrictions . . . . .
Maximum boiler-side flow rate .
Filling the domestic water tank .
Start-up and operation . . . . .
Start-up checklist . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
26
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Water heater temperature adjustment
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
26
26
26
26
26
27
Setting the control . . . . . . . . . . . . . . . . . . . . . . . . . 27
Hot Water Can Scald! . . . . . . . . . . . . . . . . . . . . . . . 27
8
Maintaining domestic water temperature in the supply piping
Time delay at fixtures . . . . . . . . . . . . . . . . . . . . . . .
Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Components required . . . . . . . . . . . . . . . . . . . . . . .
Connecting to the water heater . . . . . . . . . . . . . . . . . .
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potential problems . . . . . . . . . . . . . . . . . . . . . . . . .
.8
.8
.8
.8
.8
10
10
10
Boiler-side piping
11
Connecting to a low-pressure steam boiler
18
Water heater maintenance
28
ANNUAL start-up by qualified service technician . . . . . . . 28
Drain the water heater if necessary during shutdown periods . 28
Troubleshooting
29
Troubleshooting procedures
29
Preparation for troubleshooting . . . . . . . . . . . . . . . . . 29
Replacement parts
38
®
Rating - AQUA PLUS Series 2
39
Ratings with 200°F boiler supply water
40
Ratings with 190°F boiler supply water
41
Ratings with 180°F boiler supply water
42
Dimensions
43
Filling the piping . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Boiler-side wiring and controls
Wiring requirements. . . .
Circulators . . . . . . . . .
Zone Valves . . . . . . . . .
Wiring to the water heater.
Wiring options . . . . . . .
Use domestic priority . . .
2
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
20
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
20
20
20
20
20
20
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Please read before proceeding
Failure to adhere to the guidelines on this page can
result in severe personal injury, death or substantial
property damage.
Hazard definitions
The following defined terms are used throughout this
manual to bring attention to the presence of hazards
of various risk levels or to important information
concerning the life of the product.
Indicates presence of hazards that will
cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that can
cause severe personal injury, death or
substantial property damage.
Indicates presence of hazards that will
or can cause minor personal injury or
property damage.
Indicates special instructions on installation, operation or maintenance that are
important but not related to personal
injury or property damage.
This manual provides installation and
operation guidelines for Weil-McLain
AQUA PLUS® indirect water heaters.
The installer is responsible for ensuring
that the installation complies with this
manual, the boiler manual and all applicable codes.
Read all instructions before installing. Failure to follow all instructions in proper order can cause severe personal injury, death or
substantial property damage.
When servicing water heater
•
•
Operating restrictions
•
•
•
•
When calling or writing about the water
heater — Please have the water heater
serial number from the serial number
label, located on the back side of the
water heater, adjacent to the rating plate.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
Part number 633-600-020/0918
Maximum domestic hot water temperature: residential sizes
— 160°F, commercial sizes — 180°F. Pay attention to the
water temperature warnings throughout this manual.
Maximum boiler water temperature — 200°F.
Maximum working pressure for tank — 150 PSIG.
Water chemistry limits:
• hardness — less than 6 grains/gal.
• pH — above 6 and less than 8.
• chlorides — less than 200 ppm.
Boiler water restrictions
•
•
Massachusetts installations — The
water heater must be installed by a licensed plumber. The installation must
follow all Massachusetts code requirements. The domestic water piping must
comply with the piping shown in this
manual. See “Domestic water piping,”
page 6, for details and code requirements.
To avoid electric shock, disconnect electrical supply before
performing maintenance.
To avoid severe burns, allow water heater to cool before performing maintenance.
•
•
Thoroughly flush the boiler system (without water heater
connected) to remove sediment.
The water heater heat exchanger can be damaged by build-up
or corrosion due to sediment.
Boiler water (including additives) must be practically nontoxic, 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.
• Follow boiler manual instructions for antifreeze usage.
• Do not use automotive, ethylene glycol or petroleumbased antifreeze. Do not use any undiluted antifreeze.
Location
•
•
•
This water heater is not intended for outdoor installation.
Install the water heater so if the tank or any connections
should leak, the water flow will not cause damage to area
near water heater, or to lower floors of structure. When such
locations cannot be avoided, install a suitable drain pan under
water heater. Drain pans are available at your local plumbing
supply store.
This product is designed for vertical installation only.
3
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Pre-installation
Codes
Figure 1
Clearance recommendations
1. Installation must conform with instructions in this
manual and, where applicable:
• local, state, provincial, and national codes, laws,
regulations and ordinances.
• in Canada — B149.1 or B149.2 Installation
Code - latest edition.
2. AQUA PLUS ® water heaters are exempt from
ASME Section VIII, Division 1 Code construction
per Interpretation VIII-1-86-136. Check with local
codes for applicability.
3. Where recommendations in this manual differ from
local or national codes, local or national codes take
precedence.
Code restrictions
National Standard Plumbing Code
1. Single-wall heat exchanger in 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.
Recommended clearances
Uniform Plumbing Code
Clearance to combustible materials
1. Single-wall heat exchangers are permitted 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.
c. Exception: Steam complying with #a, above.
d. The equipment is permanently labeled to indicate that only additives recognized as safe by the
FDA shall be used in the heat transfer medium.
2. Other heat exchanger designs may be permitted
where approved by the Administrative Authority.
1. Provide at least ½” clearance between all hot water pipes and combustible materials.
4
Installation location must provide adequate clearances for servicing and
proper operation of the water heater. See Figure 1.
• 1” clearance is permissible to either side of water heater, but the Instruction label or other labels may be hidden.
• Top (vertical) clearance is 12” minimum.
• Refer to boiler manual for boiler clearances.
Water heater placement
1. Read and comply with “Location,” page 3 of this manual.
2. Select a convenient location for the water heater, based on domestic
and boiler piping hook-ups.
3. Keeping the distance between boiler and water heater short will:
• reduce piping heat loss.
• provide minimum friction loss.
Install levelling legs
1.
2.
3.
4.
Carefully tip the water heater onto its side.
Screw the four levelling legs into the base.
Return the water heater to the upright position and set in place.
Adjust the legs as necessary to level the water heater.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Pre-installation
(continued)
— Product Manual
Domestic water piping requirements
1. Install unions on all piping for easy removal of water heater.
2. 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. When the supply pressure is higher than 70 PSIG, install a pressure reducing valve on cold water supply line to prevent water loss
through T&P relief valve. A thermal expansion tank is also required.
4. If the water heater will replace a tankless coil in the boiler, disconnect piping to coil or remove coil from boiler and replace with
a cover plate. Allow water to drain from coil. Do not plug the
tankless coil.
Plugging tankless coil inlet and outlet will result in severe
personal injury, death or substantial property damage.
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.
Boiler water restrictions
Hot Water Can Scald!
•
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald
and cause permanent injury.
•
Children, elderly, and infirm or physically handicapped persons are more likely to be permanently
injured by hot water. Never leave them unattended
in bathtub or shower. Never allow small children to
use a hot water tap or draw their own bath.
1. Read the WARNINGS under “Boiler water restrictions,” page 3.
•
•
If anyone using hot water in the building fits
the above description, or if state laws or local
codes require certain water temperatures at hot
water taps, you must take special precautions:
•
Use lowest possible temperature setting.
•
Install some type of tempering device,
such as an automatic mixing valve, at
hot water tap or water heater. Automatic
mixing valve must be selected and installed
according to valve manufacturer’s recommendations and instructions.
Water passing out of 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 (provided
with water heater) and a thermostatic mixing valve
(provided by installer) is required.
Part number 633-600-020/0918
5
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Domestic water piping
Piping overview
Figure 2
DHW piping
THERMAL EXPANSION TANK — If a
backflow preventer, check valve, or pressure reducing valve is piped on cold water
inlet of water heater, you must install an
expansion tank on cold water supply line
to prevent normal thermal expansion
from repeatedly forcing open T&P relief
valve.
The T&P relief valve is not intended for
constant duty, such as relief of pressure
due to repeated normal system expansion. Refer to expansion tank manufacturer’s instructions for proper sizing.
Failure to comply could result in severe
personal injury, death or substantial
property damage.
General applications
1. Figure 2 — This piping configuration can be used in
most cases, except where local codes require special
components or piping not illustrated.
2. Some codes may require the items listed as optional,
such as a vacuum breaker on the inlet line, or recirculation piping.
Massachusetts applications
1. For Massachusetts code applications, or as
required elsewhere by local codes, install the following options.
a. Thermal siphon on DHW inlet and outlet.
b. Vacuum breaker on domestic water inlet line.
c. Recirculation — Massachusetts code applications require recirculation piping or heat-traced
piping if the distance from the water heater to
the furthest fixture exceeds 100 feet. See page 8
for details.
Figure 3
Piping connection sizes
Connections (inches NPT)
Model
AQUA PLUS®
6
DHW
in/out
Boiler
water
in/out
Recirculation
tapping
35
¾
1
¾
45
¾
1
¾
55
¾
1
¾
85
1
1
¾
105
1
1
¾
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Domestic water piping
— Product Manual
(continued)
LEGEND for Figure 2, page 6
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 its discharge
piping. Improper placement and piping of T&P relief valve can cause severe personal injury, death or
substantial property damage.
Domestic water supplied to fixtures that could pose
an injury hazard due to high temperature, such as
showers and faucets, should be equipped with a
temperature regulating device, such as an anti-scald
mixing valve.
When the supply pressure is higher than 70 PSIG,
install a pressure reducing valve on cold water
supply line to prevent water loss through T&P relief
valve. A thermal expansion tank is also required.
This symbol, where used in this manual, indicates the
item is required by Massachusetts code.
11 Temperature - Electronic Control
12 Mixing valve —
•
When the water supply pressure is higher than
70 PSIG, install a pressure-reducing valve on the cold
water supply line to prevent leakage from the T & P
relief valve. A thermal expansion tank is also required.
1 Domestic cold water inlet connection — see Figure 3, page 6 for size
ure 3, page 6 for size
3 Sensor cover — temperature sensor behind cover.
4 Boiler water inlet to coil — see Figure 3, page 6 for size
5 Boiler water outlet from coil — see Figure 3, page 6 for
size
6 Drain valve — provided by installer
• Install a drain valve on the DHW inlet to the water heater
as shown.
7 Piping from drain valve
• Pipe from drain to floor drain, if available.
8 T&P valve connection
See Replacement parts for thermostatic mixing valves
available from Weil-McLain.
13 Domestic cold water supply
This symbol indicates the item is optional, unless
required by applicable codes.
2 Domestic hot water outlet connection — see Fig-
— RECOMMENDED
14 Domestic mixed-temperature water supply to
system (when used — requires mixing valve)
15 Domestic high-temperature hot water supply to
system
16 Heat trap loops (12” minimum) —
17 Isolation valves
18 Thermal expansion tank —
•
REQUIRED if cold water line is equipped with a backflow
preventer or pressure reducing valve — see EXPANSION
TANK WARNING on page 6.
19 Shock arrester —
9 T&P relief valve — supplied with water heater
•
•
Dishwashers, clothes washers, and fast-closing positive
shutoff valves incorporated in the system all contribute to creating water shock. Install a water hammer
arrester to prevent damage to pipes and appliances.
See control manufacturer’s instructions for application and installation.
Use only the T&P valve supplied with the water heater.
See Replacement parts for part number.
Install the T&P relief valve in the top center tapping, as
shown.
10 T&P relief valve discharge piping —
• must be made of material serviceable for temperatures
of 250°F or greater.
• must be directed so that hot water flows away from all
persons.
• must be directed to a suitable place for disposal.
• must be installed so as to allow complete draining of the
T&P relief valve and discharge line.
• must NOT be excessively long — using more than 2
elbows or 15 feet of piping can reduce discharge capacity.
• must NOT be directly connected to a drain — terminate
discharge piping within 6” from floor — refer to local
codes.
• must NOT be plugged, reduced or restricted.
• must NOT be subjected to freezing.
Part number 633-600-020/0918
20 Unions
•
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.
21 Backflow preventer —
—
— (required
for Commonwealth of Massachusetts)
22 Vacuum breaker —
23 Pressure reducing valve —
•
REQUIRED when the supply pressure is higher than
70 PSIG — A thermal expansion tank is also required.
7
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Recirculation
Massachusetts code applications require recirculation piping or heat-traced piping if the distance
from the water heater to the furthest fixture exceeds
100 feet.
Maintaining domestic water
temperature in the supply piping
1. Recirculation is used to reduce wait time for water use, to
minimize hot water and energy waste caused during the
waiting period, and to prevent degradation of the system
supply water temperature. ASPE recommends recirculation
when the distance from the water heater to the furthest fixture exceeds 100 feet or the time lag for hot water to reach a
fixture(s) exceeds 30 seconds.
2. Consult local codes and American Society of Plumbing
Engineers (ASPE) Domestic Water Heating Design Manual,
1998, for further information.
2. These branches must be balanced to prevent pipe erosion
and unacceptable time delays at some fixtures.
3. Balancing options include circuit setters, memory stop valves
or factory preset devices (with flow metering provision in
the piping).
Components required
1. For residential applications, consult circulator manufacturer’s
data for circulator selection and additional components
required.
2. On most commercial systems, install the devices shown in
Figure 5, page 9, and any other devices or piping methods
required by local codes.
a. The check valves are required to prevent fixtures from
taking hot water through the return lines.
b. Shutoff valves are needed to allow cleaning and replacing
balancing devices.
Time delay at fixtures
1. Figure 4, page 9 is from the ASPE Domestic Water Heating
Design Manual, 1998. It shows the time required for usable
hot water to arrive at a fixture based on the fixture flow rate
(available from industry and manufacturer’s data) and the
length and diameter of the dead-end branch pipe supplying
the fixture.
2. The time lag should generally not exceed 30 seconds.
3. For residential and office applications, the owner may prefer
a limit of 10 seconds.
c. Include strainers to remove sediment which could
damage the circulator and / or affect the flow balancing
devices.
3. Size the circulator and piping based on the temperature drop
allowed between the water available at the water heater and
the water delivered at the fixture.
a. The return piping will almost always be smaller than the
supply piping, but should never be smaller than ½” to
prevent problems with the circulator.
4. You can use Figure 4 as a guide to determining the location
of circulation return lines relative to fixtures.
4. Make provision for removal of air in all return lines. Where
the returns cannot be vented by topmost fixtures in the
system, install automatic air venting at the top of the return
piping.
Balancing
Connecting to the water heater
1. When multiple branches are connected to the supply piping,
each branch must be connected to the recirculation system.
1. Install the domestic water components as shown in Figure 2, page 6.
a. At each of these connections to the return piping, install
shutoff valves, a flow metering device, check valve and a
strainer as shown in Figure 5, page 9.
2. See Figure 6, page 10 for the piping required to the water
heater.
b. Check local codes for specific installation requirements.
— Continued on page 10 —
8
Part number 633-600-020/0918
®
AQUA PLUS Series 2
Recirculation
Figure 4
INDIRECT-FIRED WATER HEATERS
— Product Manual
(continued)
Time lag to obtain hot water at fixture for branch lengths of 10 and 25 feet (ASPE
Domestic Water Heating Design Manual)
Time in seconds required to get hot water at fixture (from ASPE)
Fixture flow rate (GPM) -
0.5
Piping length (feet) Copper pipe
Steel pipe
CPVC pipe
1.5
2.5
4.0
10
25
10
25
10
25
10
25
½”
25
63
8
21
5
13
3
8
¾”
48
119
16
40
10
24
6
15
½”
63
157
21
52
13
31
8
20
¾”
91
228
30
76
18
46
11
28
½”
64
159
21
53
13
62
8
20
¾”
95
238
32
79
19
48
12
30
NOTE: Select branch size and length for less than 31 seconds delay.
Figure 5
Recirculation components
Part number 633-600-020/0918
9
®
AQUA PLUS Series 2
Recirculation
INDIRECT-FIRED WATER HEATERS
— Product Manual
(continued)
Components
Figure 6
Recirculation piping
Circulator (Figure 6, item 1)
1. Little flow is required to maintain a temperature
in the piping.
2. Size of circulator depends on minimum flow requirements of the tempering valve.
3. Minimum flow rates of the tempering valve must
be maintained.
Aquastat (Figure 6, item 2)
1. Used to control the on-off position of the circulator. Aquastat is set 5° to 10° lower than mixed water
outlet of the mixing valve (#7).
2. The circulator cannot run continuously as bypass
through the mixing valve will eventually allow the
temperature on the piping to climb to the water
heater temperature during draw periods.
Check valves (Figure 6, items 3–6)
1. Assure the flow of water in one direction.
2. Each check valve functions as follows:
a. #3 and #4 prevent bypass in the event of pressure drop.
b. #5 prevents thermal siphoning of hot water to
the cold water supply.
c. #6 prevents flow of cold water to the tempered
water supply. A draw of tempered water will not
result in flow of cold water into the return loop.
Operation
1. During period of normal use (fixtures on) — Circulator is off. There is no flow through #6, there is flow
through #5 equal to the flow at the fixtures, there is
flow through #3 and/or #4 equal to flow at fixture.
2. When all fixtures are off — Circulator is off. There is
no flow through #3, #4, #5 or #6. Water temperature
in piping is cooling.
3. When temperature at aquastat #2 falls 10° below
temperature to be maintained — Circulator is on.
There is flow through #6 equal to the minimum
required by the mixing valve, flow through #3 and
#4 equals the flow of the circulator. There is no
flow through #5.
4. Aquastat reaches temperature — Circulator is off.
There is no flow through #3, #4, #5 or #6.
10
Potential problems
1. Missing check valves #3 or #4 — Extreme pressure drop can cause
reverse flow of water; hot to cold supply or cold to hot supply.
2. Missing check valve #5 — Hot water can migrate from the water heater
back through the cold water supply.
3. Missing check valve #6 — Cold water can be forced back through the
tempered water supply when a fixture is opened.
4. No aquastat #2 — Circulator runs continuously. Small amount of
water will pass through mixing valve. Eventually all hot water is flowing through valve. Recirculated water through cold port, hot water
through hot port.
5. Circulator too small — Mixing valve performance erratic.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Boiler-side piping
Figure 7
Zoning with circulators — direct-connected system piping
Notes
•
•
•
Place circulators at beginnings of zones. Placing
them at the ends of zones
could result in heating idle
zones.
Size manifold piping for
total flow of all zone circulators.
Locate flow / check valves
as close as possible to water
heater boiler side connections — to reduce heat loss
between cycles.
Wiring
•
WMCR zone controller,
optional priority — Figure 25, page 23.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. See boiler manual for specific details on installing
the boiler.
Part number 633-600-020/0918
Recommended flow rate and minimum boiler-side pipe size
Heater model
GPM
Pipe size
Heater model
GPM
Pipe size
35
8
1”
85
14
1¼” *
45
8
1”
105
14
1¼” *
55
8
1”
Requires 1¼”x1” reducers at water heater
11
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side piping
Figure 8
— Product Manual
(continued)
Zoning with circulators — primary/secondary system piping
Notes
•
•
•
Place circulators at beginnings of zones. Placing
them at the ends of zones
could result in heating idle
zones.
Size manifold piping for
total flow of all zone circulators.
Locate flow / check valves
as close as possible to water
heater boiler side connections — to reduce heat loss
between cycles.
Wiring
•
WMCR zone controller, optional priority —
Figure 25, page 23.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. See boiler manual for specific details on installing
the boiler.
12
Recommended flow rate and minimum boiler-side pipe size
Heater model
GPM
Pipe size
Heater model
GPM
Pipe size
35
8
1”
85
14
1¼” *
45
8
1”
105
14
1¼” *
55
8
1”
Requires 1¼”x1” reducers at water heater
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side piping
Figure 9
— Product Manual
(continued)
Zoning with zone valves — direct-connected system piping
Notes
•
•
•
Place circulators at beginnings of zones. Placing
them at the ends of zones
could result in heating idle
zones.
Size manifold piping for
total flow of all zone circulators.
Locate flow / check valves
as close as possible to water
heater boiler side connections — to reduce heat loss
between cycles.
Wiring
•
WMZV zone controller, optional priority —
Figure 26, page 23.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. See boiler manual for specific details on installing
the boiler.
Part number 633-600-020/0918
Recommended flow rate and minimum boiler-side pipe size
Heater model
GPM
Pipe size
Heater model
GPM
Pipe size
35
8
1”
85
14
1¼” *
45
8
1”
105
14
1¼” *
55
8
1”
Requires 1¼”x1” reducers at water heater
13
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side piping
— Product Manual
(continued)
Figure 10 Zoning with zone valves — primary/secondary system piping
Notes
•
•
•
Place circulators at beginnings of zones. Placing
them at the ends of zones
could result in heating idle
zones.
Size primary piping for
total flow of all zone circulators.
Locate flow / check valves
as close as possible to water
heater boiler side connections — to reduce heat loss
between cycles.
Wiring
•
WMZV zone controller,
optional priority — Figure 26, page 23.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. See Boiler Manual for specific details on installing
the boiler.
14
Recommended flow rate and minimum boiler-side pipe size
Heater model
GPM
Pipe size
Heater model
GPM
Pipe size
35
8
1”
85
14
1¼” *
45
8
1”
105
14
1¼” *
55
8
1”
Requires 1¼”x1” reducers at water heater
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side piping
— Product Manual
(continued)
Figure 11 Dedicated single-boiler piping
Notes
•
•
•
Place circulators at beginnings of zones. Placing
them at the ends of zones
could result in heating idle
zones.
Size manifold piping for
total flow of all zone circulators.
Locate flow / check valves
as close as possible to water
heater boiler side connections — to reduce heat loss
between cycles.
Wiring
•
Connect water heater control wires to boiler’s T-T
terminals or heat demand
connection.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. See boiler manual for specific details on installing
the boiler.
Part number 633-600-020/0918
Recommended flow rate and minimum boiler-side pipe size
Heater model
GPM
Pipe size
Heater model
GPM
Pipe size
35
8
1”
85
14
1¼” *
45
8
1”
105
14
1¼” *
55
8
1”
Requires 1¼”x1” reducers at water heater
15
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side piping
— Product Manual
(continued)
Figure 12 Multiple water heaters — domestic water piping
Failure to install automatic
mixing valve where recommended can result in severe
personal injury or death.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. Wire water heater controls
in series when connecting to boiler controller or
boiler T-T terminals.
Figure 13 Alternate methods of revers-return piping and Easy-Fit® Manifold detail
3. Install automatic mixing
valve at either the system
hot water connection or at
each water heater.
4. See page 8 through page 10
for additional recirculation information and piping details.
16
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side piping
— Product Manual
(continued)
Figure 14 Multiple water heaters and dedicated multiple boilers — boiler water piping
Notes
•
See legend and details in
Figure 12, page 16.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. See boiler manual for specific details on installing
the boiler.
Part number 633-600-020/0918
17
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Connecting to a low-pressure steam boiler
Special considerations
When designing steam and domestic hot water systems, there are some
key issues that must be taken into consideration during the initial design phase. By designing the system properly from the start, you can
avoid problems and have a hot water loop in a steam boiler system.
•
•
•
•
•
•
•
•
The domestic water demand should preferably not exceed 1/3
of the steam boiler capacity. Larger demand may cause difficulty
obtaining steam as needed.
Keep the loop temperature below the flash point. Flashing can result
in noise and circulator damage or shortened life.
Be sure the loop is completely closed, with no automatic or manual
air vents, or anything that could allow air to enter the system when
the pump shuts off.
Pipe supply from one side of the boiler, return to the opposite
side as shown.
Supply from a tapping that is high enough to prevent introducing
sediment into the piping and circulator yet still below the water
line. Avoid the mud leg of the boiler.
Use an all bronze circulator.
• Avoid wet rotor circulators. Select a circulator with a large
volute, such as a typical 3-piece circulator.
• This will reduce clogging and will resist the corrosion potential
from the steam condensate.
Make sure the circulator is properly sized. If the circulator runs
too far out on its curve, cavitation potential increases significantly.
Use (2) flow / check valves as shown to reduce the potential for
gravity circulation.
• DO NOT use spring-loaded check valves in place of the
flow / check valves shown in Figure 16, page 19.
Installation and start-up of water heaters
connected to steam boilers
1. See Figure 16, page 19, for suggested piping schematic.
2. Pipe the domestic water connections to the water heater per “Domestic water piping,” page 6.
Boiler connections for the water heater must be below
the water line. DO NOT use the gauge glass tapping or
a low water cut-off tapping if a LWCO is installed there.
For steam piping, refer to the steam boiler manual.
DO NOT install an air vent anywhere in the piping. The
piping must be air tight.
3. Wire the water heater and circulator to the boiler per suggested
wiring in Figure 15. The water heater must be wired and ready to
operate before proceeding. Note that the L4006A aquastat is located
in the boiler and sets a boiler operating temperature when there is
no call for steam heating.
To fill the boiler and water heater:
1. Follow the procedure given in Figure 16, page 19 to fill the water
heater piping.
2. Follow the boiler manual instructions to fill the steam boiler.
18
Figure 15 Typical wiring for connection to lowpressure steam boiler
Install the Honeywell L4006A aquastat in the boiler,
below the water line. Set for a temperature of 180 to
190°F to control boiler temperature when there is no
call for steam heating.
Valve 7, the memory stop valve, must
be supplied, piped and adjusted as instructed. This valve allows cooler return
water to mix with the hot water from
the steam boiler. The valve is set to yield
approximately 180°F water entering the
circulator. Higher temperature water
could cause cavitation in the circulator,
damaging the impeller and shortening
circulator life.
DO NOT connect the piping to the boiler’s mud leg. This would probably cause
excessive sediment to enter the water
heater piping, damaging the circulator.
The strainer in the circulator suction line
must be serviced regularly. NOTE that
noise from the circulator is a likely sign
that the strainer is restricting circulator
flow, causing cavitation.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Connecting to a low-pressure steam boiler
(continued)
Figure 16 Low pressure steam boiler application — Domestic water heating using water pumped from steam boiler
Notes
•
Locate flow / check valve as
close as possible to water
heater boiler side connections — to reduce heat loss
between cycles.
Use memory stop valve 7 to
blend some of the water returning to the boiler with the
hot water coming from the
boiler. This will reduce the
possibility of flashing (cavitation) in the circulator. Slowly
open valve 7 until temperature
gauge 8 reads 200°F.
Set the memory stop on valve 7
after adjusting. Attach a tag to
the valve warning not to close
or change valve position.
NOTE — If the boiler water
level should drop below either the water heater boiler
water supply or return line,
the filling procedure will
have to be repeated.
1. This drawing is conceptual
only. It shows representative piping components
and layout. Weil-McLain
does not represent that this
drawing meets any particular mechanical or building codes. The installer is
responsible for inclusion
of all required safety devices, or other miscellaneous piping hardware not
shown on drawing. The
installer is responsible for
proper sizing / selection of
all hardware shown on this
diagram.
2. See boiler manual for specific details on installing
the boiler.
Part number 633-600-020/0918
Filling the piping
Step 5 Close valve 7. Then open valve 10.
1. Parts of the boiler water piping to the
water heater may be higher than the water line, depending on the height of the
water heater boiler supply connection.
The piping must be air tight to prevent air
from pocketing at the top of the piping,
stopping flow.
2. The boiler MUST be filled and ready to
operate before proceeding. Follow the
boiler manual to fill the boiler.
3. Follow the procedure below to fill the
boiler-to-water heater piping. See Figure 16.
Step 6 Open valve 3. Water will flow through
the circulator line, the water heater
coil and the return piping, then out
through valve 4 to drain. Let water run
until all air has been removed from the
line. Close valve 4. Then close valve 3.
Remove hoses.
Step 7 Follow the instructions in “Water
heater filling and start-up,” page 26,
to fill the domestic water side of the
water heater.
Step 8 Open valve 7 about ¼ turn for an
initial setting.
Step 1 Close isolation valves 5 and 6 to isolate
the boiler.
Step 9 Open isolation valves 5 and 6. Make
sure the boiler water level is correct
per the boiler manual.
Step 2 Close valve 3 and open valve 4. Connect a cold water supply hose to
valve 3. Connect a hose from valve 4
to a drainable location.
Step 10 Start the boiler per instructions given
in the boiler manual. Allow boiler to
begin steaming.
Step 3 Close valve 10. Open valve 7.
Step 11 Start the DHW circulator. Watch the
temperature at gauge 8. Adjust valve 7
until gauge 8 reads about 180°F with
system at steady operation.
Step 4 Open valve 3. Water will flow through
valve 7 and out through valve 4 to
drain. Open valve 11. Let water run
until all air has been removed from
the line through valve 11. Close valve
11. Close valve 4. Then close valve 3.
Step 12 Continue checking under varying
DHW demand conditions to ensure
system will operate as required.
19
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Boiler-side wiring and controls
Electrical shock hazard — Can cause
Figure 17 Wiring the control “General Connection”
severe personal injury, death or substantial
property damage. Disconnect power before
installing and / or servicing.
7RWDQN
WHPSHUDWXUHVHQVRU
1. All wiring must be a minimum of 18 gauge and installed
in accordance with:
• U.S.A. — National Electrical Code, ANSI/NFPA 70
- latest edition and any other national, state or local
code requirements having jurisdiction.
• Canada — CSA C22.1 Canadian Electrical Code Part
1 and any other national, provincial and local code
requirements having jurisdiction.
2. If original wire as supplied with appliance must be replaced, Type 90° C 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 are shown with no power applied
— off-the-shelf condition.
Circulators
Size priority relay for total amp draw of all circulators.
7R=RQH
RU
%RLOHU
&RQWURO
287387&217$&76
Wiring requirements
9$&,1387
$&
$&
9$&
,QSXW
1. Connect a 24VAC power source to the “24VAC Input” terminals.
2. Connect the “Output Contacts” to the zone or boiler control’s
domestic water input.
3. Eliminate stray voltage in the power circuit by connecting the
24VAC power to AC2 and grounding AC1. Confirm correct connections by verifying 24VAC between AC1 and AC2.
Zone Valves
Size transformer for maximum load of all zone valves.
The “Output Contacts” are isolated contacts that close
when the control calls for heat.
Wiring to the water heater
Field connections to the water heater control are for 24VAC
only, connecting to the two-pole terminal block shown in
Figure 17.
Hot Water Can Scald – Connecting to greater
than a 24 volt circuit will cause hot water that
can cause severe personal injury.
®
Figure 18 Wiring tank control to the AquaBalance boiler
control.
7HUPLQDOV
7R
%RLOHU
&RQWURO
Wiring options
1. This manual shows wiring only for use of typical Circulator Zone Controller or Zone Valve Zone Controller, wire
per manufacturer’s instructions.
2. Other wiring methods may be acceptable and are left to
the installer.
Use domestic priority
1. When possible, set controls to provide domestic priority
— that is, on a call for domestic water the control switches
from space heating to DHW only.
2. Domestic priority ensures the fastest possible response to
the DHW call for heat.
3. The smaller the water heater, the greater the need for
rapid response.
20
9$&
,QSXW
$FX7HPS
:0
FRQWURO
$TXD%DODQFHERLOHU
&RQWUROWHUPLQDOV
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side wiring and controls
Figure 19 Wiring tank control to the CGa (1135-05/606),
— Product Manual
(continued)
Figure 20 Wiring tank control to the ECO (1176-120/121)
CGi (1135-615), and the EG Water (1135-605)
boiler control.
boiler control.
Çä
Èä
)FBU*OQVU
5
5
5
767$7
%/
%/
5
*
%.
5P
(SPVOE
4DSFX
1
3FE
%.
#MBDL
$FX7HPS
:0
FRQWURO
9$&
,QSXW
-DFNHWRSHQLQJ
ERLOHUOHIWVLGH
#MBDL
1
(SBZ
#MBDL
'*&-%
8*3*/(
0SBOHF
"EEJUJPOBMMJNJUTJGVTFE
$POUSPMXJMMBVUPNBUJDBMMZ
SFTFU
7R
%RLOHU
&RQWURO
5)&3.045"5
:
nä
"EEJUJPOBMMJNJUTJGVTFE
8JMMSFRVJSFNBOVBMSFTFU
&
%.
nä
'BDUPSZKVNQFST SFNPWFJGVTJOHMJNJUT
< %.
*
Çä
1*-05
#63/&3
:
2
Èä
7R=RQH
RU
%RLOHU
&RQWURO
$FX7HPS
:0
FRQWURO
0VUEPPSUFNQTFOTPS
JGVTFE
9$&
,QSXW
&*D&*L (*
&RQWURO
WHUPLQDOV
1
1
'MVFUF
TFOT
1
-PXXBUFSDVUPGG JGVTFE
&
(&2ERLOHU
O
L O
%JTQMBZJOUFSGBDF
QBOFM
Figure 21 Wiring tank control to the Evergreen (1176-160) and SlimFit 550-750 (1176-170) boiler control.
'VTF
BNQ
WBD
8
3
3
8
@
1
8IJ
3FE
1
1
#MVF
$PNNPO
)RUUHSOD
&RQWURO3
1
0SBOHF
1
&$1&$
7KLVG
JHWVZ
WKLVG
1
1
'BDUPSZKVNQFST SFNPWFJGVTJOHMJNJUT
$"65*
VZLWFK
/05*$&
1
FRQGXF
(SBZ
1
1
1
#MBDL
1
#PJMFSUP#PJMFS*O
NVMUJQMFCPJMFSTPOMZ
#PJMFSUP#PJMFS0VU
NVMUJQMFCPJMFSTPOMZ
8
$FX7HPS
:0
FRQWURO
7R=RQH
RU
%RLOHU
&RQWURO
3
1
::
#-
9$&
,QSXW
1
1
(YHUJUHHQERLOHU
&RQWUROWHUPLQDOV
Part number 633-600-020/0918
21
®
INDIRECT-FIRED WATER HEATERS
AQUA PLUS Series 2
Boiler-side wiring and controls
Figure 22 Wiring tank control to the GV90+ (1135-700)
— Product Manual
(continued)
Figure 24 Wiring tank control to the Ultra (1176-100)
boiler control.
boiler control.
.PEVMBUJOHJOQVU
o7%$
3FE
#MVF
4ZTUFNTVQQMZ
UFNQFSBUVSFTFOTPS
$FX7HPS
:0
FRQWURO
$PNNPO
4ZTUFNSFUVSO
UFNQFSBUVSFTFOTPS
1
0SBOHF
'BDUPSZKVNQFST SFNPWFJGVTJOHMJNJUT
&
5
5
%/
%/
7R
%RLOHU
&RQWURO
"EEJUJPOBMMJNJUTJGVTFE
$POUSPMXJMMBVUPNBUJDBMMZ
SFTFU
$FX7HPS
:0FRQWURO
9$&
,QSXW
7R=RQH
RU
%RLOHU
&RQWURO
7RWKHUPRVWDW
7R
*URXQG
6FUHZ
5HG
KRVH
1
QJO
DPOOFDUPS
UISPVHI
DBCJOFU
*9ERLOHU
&RQWUROWHUPLQDOV
:KLWH
KRVH
#MBDL
1
%/
%.
(SBZ
"EEJUJPOBMMJNJUTJGVTFE
8JMMSFRVJSFNBOVBMSFTFU
9$&
,QSXW
'MV
T
1
1
$LUSUHVVXUH
VZLWFK
-PXXBUFSDVUPGG JGVTFE
8OWUDERLOHU
&RQWUROWHUPLQDOV
%JTQMBZJOUFSGBDF
QBOFM
Figure 23 Wiring tank control to the WM97+ (1176-112/113) boiler control.
% % % %
*URXQGZLUH
%
%
%
&#.
)FBUFYDIBOHFS
PVUMFUUFNQ
TFOTPS
'MVFUFNQTFOTPS
)FBUFYDIBOHFS
JOMFUUFNQ
TFOTPS
&
&
&
&
&
3LQ
%
(BT
WBMWF
%
$JSDVMBUPSJO$8)VOJU
XIFO$8)JTJOTUBMMFE
=RQH
FLUFXODWRU
&
&
&
=RQH
FLUFXODWRU
/
3LQ
&
&
&
(SPNNFU
QBOFMT
#PJMFSS
BUPS
DJSDVMBUPS
)POFZXFMM
%
%
%
%
$8)TFOTPSCPUUPN
015*0/"- $8)0/-:
%
%
$
$
5SBOTGPSNFS
$8)TFOTPSUPQ
$
$
$
(SPNNFU
$
$
$
$
$
9$&WR&,5&8/$725 6
=RQH
FLUFXODWRU
FRQQHFWWR
'+:FLUF
ZKHQXVHG
=21(
=21( =21(
7R
%RLOHU
&RQWURO
:0
&RQWURO
WHUPLQDOV
/ 1
&,5&
$
$
$
$
/ 1
&,5&
$ $
/ 1
&,5&
/,1(92/7$*(7(50,1$/6
/2:92/7$*(7(50,1$/6
1 *
/,1(
+ 1 *
9$&WRERLOHU
',5(&7&211(&7('²WKH
OLQHYROWDJHRXWSXWVDUHQRWXVHG
35,0$5<6(&21'$5<²
-XPSHUIURP/WR/RIHDFKRIWKH
V\VWHP]RQH&,5&RXWSXWVWKHQ
FRQQHFWWKHV\VWHPFLUFXODWRUWR
DQ\RIWKHV\VWHP&,5&RXWSXWV
0/0''
TXJUDI
(SPNNFU
%
%
%
%
&
%
-DFNHW
VFUHZ
*HOJUFSGMBNFSPE
-PX
XBUFS
DVUPGG
=21(9$/9(6<67(06
&
$8)DJSDVMBUPSFYUFOTJPOIBSOFTT
DPOOFDUXIFO$8)JTJOTUBMMFE
$FX7HPS
:0
FRQWURO
5 &
9$&
2'7
7(03
0$1
/,0,7
$872
/,0,7
$/$50
"EEJUJPOBMMJNJUT
0VUEPPS SFNPWFKVNQFST
TFOTPS
JGVTFE
JGVTFE
TFF/PUF
"MBSNDPOUBDUT
&
&
127(&RPSDQLRQ:DWHU+HDWHU &:+ LVRSWLRQDO
&
&
7"$GPSUTUBU
&#.'BTDPP
#MPXFS
6HUYLFH
VZLWFK
)POFZXFMM
#MPXFS
9$&
,QSXW
22
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Boiler-side wiring and controls
— Product Manual
(continued)
Figure 25 Wiring — zoning with circulators — DHW priority with typical Circulator Zone Controller
1. These drawings are conceptual only. It shows representative components and
wiring. Weil-McLain does
not represent that these
drawings meets any particular mechanical or building codes. The installer is
responsible for inclusion of
all required safety devices,
or other miscellaneous piping hardware not shown
on drawing. The installer
is responsible for proper
sizing / selection of all hardware shown on this diagram.
2. Follow component manufacturer’s instructions for
installation of all items
shown.
3. See boiler manual for specific details on installing the
boiler.
$FX7HPS
:0FRQWURO
7R=RQH
RU
%RLOHU
&RQWURO
5IFSNPTUBUT
7+(50267$76
&RQWURO3RUW
(OHFWURQLF
)XVH
:DWHU+HDWHU
7:
75
7:
75
7:
&RPPRQ
=RQH
=RQH
=RQH
75
7:
9$&
,QSXW
75
9
#9$
3ULRULW\21
287
;±;
=5=&
7R([SDQVLRQ
0RGXOH
=RQH
=RQH
=RQH
=RQH
3ULRULW\21
:0&5
&LUFXODWRU=RQH
&RQWUROOHU
System piping
•
•
:HLO0F/DLQ
0LFKLJDQ&LW\,1
Figure 7, page 11
Figure 8, page 12
;
;
=& =5
,VRODWHG
6ZLWFK
/ 1
3ULRULW\=RQH
/ 1
/ 1
=RQH
=RQH
9$&&LUFXODWRUV
/ 1
1
/
=RQH
9$&,1
(SE
/FVUSBM
5PCPJMFS5o5
7"$
Notes
•
•
Also refer to the Zone
Control Instructions
and Weil-McLain Boiler
Zone Wiring Guide for
further details.
Refer to Wiring requirements on page 20.
1SJPSJUZ
DJSDVMBUPS
)PU
$JSDVMBUPST
Figure 26 Wiring — zoning with zone valves — DHW priority with typical Zone Valve Zone Controller
$FX7HPS
:0FRQWURO
5IFSNPTUBU 5IFSNPTUBU 5IFSNPTUBU
[POF
[POF
[POF
7R=RQH
RU
%RLOHU
&RQWURO
System piping
9$&
,QSXW
&20
$POOFDU7"$
QPXFSMFBETUP
USBOTGPSNFSCMBDL
BOEXIJUFMFBET
77
77
77
77
;;
21
:0=9
21
3ULRULW\
]RQH
VZLWFK
=RQH9DOYH&RQWUROOHU
9$&
Figure 9, page 13
Figure 10, page 14
2))
Install all zone valves per
valve manufacturer’s instructions.
(1'6:
;
;
9$&
3ULRULW\
7"$
DPOTUBOU
UPXJSF
[POF
WBMWFT
5PDJSDVMBUPS
PSCPJMFS5o5
UFSNJOBMT
Part number 633-600-020/0918
=RQH
=RQH
5P[POF
[POFWBMWF
5PQSJPSJUZ
[POFWBMWF
:HLO0F/DLQ
0LFKLJDQ&LW\,1
•
•
=RQH
5P[POF
[POFWBMWF
5P[POF
[POFWBMWF
23
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Mounting and wiring the Control - New Installations
1. Locate the sensor leads on the top of the tank.
4. Insert the sensor wire into the channel in the
back of the control.
2. Route the sensor wire through the opening in
the rear of the control.
5. Attach the control to the top plastic cap of the
tank and secure with two (2) screws.
3. Plug the AquaPlus sensor wire into the sensor
input. The terminals are not polarity sensitive.
6. Add a third screw through the top of the control. Reinstall control cover once wiring connections are made and the control is mounted.
Refer to “Boiler-side wiring and controls” on pages 20 - 23 for wiring instructions.
24
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Setting the Control
1 Display.
During normal operation, one of two indicating lights will appear on the display. If
the control is calling for heat, the indicating light on the bottom right of the screen
will illuminate. When the water temperature reaches the control set point, the indicating light on the left of the display will illuminate indicating that the tank is up to
temperature and the control is in Standby.
Calling for Heat
Standby
2 Setting the control.
Push the setting dial to enter the Temperature Setting mode. When pressed, the
display will show ‘OFF’ or the current temperature setting. Turn the dial to select
the desired water temperature to be maintained in the water heater. See Commercial/Residential (below) for available temperature ranges. The display will
return to the operating mode (see Display above) after five seconds of inactivity.
IMPORTANT: Temperature variations can exist within the water heater. The
value displayed on the control is the approximate temperature. A typical starting adjustment point is 120°F. Test the water at the closest point of use for final
control adjustment.
Scald Hazard – Exposure to 125°F or hotter water
can cause scalding injuries. A mixing valve should be
installed on installations set at 125°F or higher.
Water temperature over 125°F (52°C) can
cause severe burns instantly resulting in
severe injury or death.
Children, the elderly, and the physically or
mentally disabled are at highest risk for
scald injury.
Feel water before bathing or showering.
Temperature limiting valves are available.
Read instruction manual for safe temperature setting.
3 Setting the Temperature / Differential.
The differential does not need to be set. The control’s advanced software algorithm determines the optimum temperature to
initiate heat calls.
4 Celsius / Fahrenheit.
To change from Fahrenheit to Celsius, push and hold the setting dial for 5 seconds. The current selection, “F” or “c” will blink
on the LED display. Release and turn the setting dial to the desired setting “F” or “c” then push the setting dial again to select it.
When the control is set for Celsius, the display will include a “c” following the temperature. Once selected, the
display will return to the current water temperature.
5 Residential / Commercial.
The control is equipped with two temperature ranges: One for residential installations (60°F-160°F) and a second for commercial
installations (60°F-180°F). To change from the Residential range to the Commercial range, remove power from the control. Then
push and hold the setting dial while restoring power. The current range, “r” or “c” will blink in the LED display. Release and turn
the setting dial to the desired range “r” or “c”, then push the setting dial again to enter the setting. Once entered, the display will
briefly show the selected setting; then the control will display “off ”. Follow the instructions above (Setting the Control) to set the
desired temperature within the selected (residential or commercial) range.
6 Error Codes.
Sensor Error
The resistance value of the sensor is out of range. Check the sensor connection to the pc board.
If the connection is good, the sensor may need to be replaced.
Self Test Error The control has failed an internal test of the hardware or software. Try cycling 24 VAC power
off and on. If the problem is resolved, the control will return to normal operation. If the error
does not clear, the control should be replaced.
Part number 633-600-020/0918
25
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Water heater filling and start-up
The installation and water chemistry must meet
the requirements below. Failure to comply could
result in damage to the water heater, causing possible severe personal injury, death or substantial
property damage.
Boiler water restrictions
•
•
•
•
Thoroughly flush the boiler system (without water heater
connected) to remove sediment.
The water heater heat exchanger can be damaged by build-up
or corrosion due to sediment.
Boiler water (including additives) must be practically nontoxic, 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.
• Follow boiler manual instructions for antifreeze usage.
• Do not use automotive, ethylene glycol or petroleumbased antifreeze. Do not use any undiluted antifreeze.
Maximum boiler-side flow rate
•
Select the boiler-side circulator carefully. The flow rate
through the boiler side of the water heater must not exceed
the values below. Higher flow rates could result in an input
above the rating of the T&P valve.
•
Models AQUA PLUS®-32, 42 and 52 - do not exceed 12 GPM.
•
Models AQUA PLUS®-80 and 105 - do not exceed 16 GPM.
Start-up checklist
❏ Verify that T&P relief valve is properly installed and
piped as directed in this manual and per local code
requirements.
❏ Verify that the DHW tank and boiler-side piping are
complete and are filled with water and pressurized.
❏ Verify that all air has been bled from both domestic and
boiler water systems.
❏ Verify that cold and hot water lines are correctly connected to domestic water system.
❏ Verify that supply and return piping from boiler is correctly connected to water heater.
❏ Check all fittings and piping for leaks.
❏ Verify that all wiring is installed correctly.
❏ Set water heater control according to system require-
ments. See “Water heater temperature adjustment,”
page 27.
❏ Start boiler according to the Boiler Manual.
❏ Verify that the boiler and water heater are operating
correctly, per “Water heater temperature adjustment,”
page 27.
❏ Review the following sections with the homeowner or
system operator:
Filling the domestic water tank
•
Water Heater Start-Up
•
Adjusting Water Heater Temperature
•
Water Heater Maintenance
1. Fill the domestic water tank with fresh water that meets the chemistry requirements above.
2. Do not exceed a fill pressure of 70 PSIG.
When the water supply pressure is higher than 70 PSIG,
make sure that a pressure-reducing valve is installed on
the cold water supply line to prevent leakage from the T&P
relief valve. A thermal expansion tank is also required.
3. Vent the piping as necessary to remove any trapped air.
Start-up and operation
1. Follow the “Start-up checklist,” page 26 to prepare for start-up.
26
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Water heater temperature adjustment
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 controller accordingly.
• Always recheck temperature after adjusting control.
When hot water is used in repeated small quantities, a “stacking”
effect can develop in hot water tank. The upper layer of water in
tank can be much hotter than lower layers.
Lowering the control setting or installing automatic mixing valves
as indicated in these instructions will reduce water temperature
levels. Consult your installer or service technician.
At no time should boiler limit control be set above 200°F.
This can cause severe personal injury, death or substantial
property damage if ignored.
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.
Hot Water Can Scald!
Setting the control
1. The water heater control is factory set to its lowest temperature.
This may or may not be suitable for your needs.
2. Push knob in to enter adjustment mode.
3. Turn control knob clockwise to increase water temperature.
4. Turn control knob counter-clockwise to reduce water temperature.
5. When decreasing temperature setting, the stored hot water must
be drawn off before checking temperature at faucet.
6. Check 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.
7. When adjusting control, be sure boiler limit control is set a minimum 20°F higher.
8. See information packed with control for more instructions.
•
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald
and cause permanent injury.
•
Children, elderly, and infirm or physically handicapped persons are more likely to be permanently
injured by hot water. Never leave them unattended
in bathtub or shower. Never allow small children to
use a hot water tap or draw their own bath.
•
Figure 27 Water heater digital temperature control
•
If anyone using hot water in the building fits
the above description, or if state laws or local
codes require certain water temperatures at hot
water taps, you must take special precautions:
•
Use lowest possible temperature setting.
•
Install some type of tempering device,
such as an automatic mixing valve, at
hot water tap or water heater. Automatic
mixing valve must be selected and installed
according to valve manufacturer’s recommendations and instructions.
Water passing out of 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 (provided
with water heater) and a thermostatic mixing valve
(provided by installer) is required.
Part number 633-600-020/0918
27
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Water heater maintenance
Boiler water — read and comply with all requirements
under “Boiler water restrictions,” page 3.
Figure 28 T&P valve operation
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.
Before operating the T&P relief valve,
make sure no one is in front of or around
the T&P relief valve discharge piping. Hot
discharge water can cause severe personal
injury or substantial property damage.
ATTENTION USER!
Have the water heater serviced at least once
annually by a qualified service technician.
Follow the maintenance procedures below at least
monthly.
Read “Water heater temperature adjustment,”
page 27.
Failure to comply with the above can result in severe personal injury, death or substantial property
damage.
Plugging T&P relief valve or discharge
piping can cause excessive pressure in the
water heater, resulting in severe personal
injury, death or substantial property damage.
MONTHLY maintenance by user
•
•
•
At least MONTHLY, visually check valves, pipes and fittings
for leaks.
Check hot water supply at several outlets. Make sure water
temperature is not too hot.
Call qualified service technician to repair leaks or address
problems.
❏ Manually operate T&P relief valve at least once a year (see
MONTHLY maintenance by user
•
•
•
At least MONTHLY, visually check valves, pipes and fittings for
leaks.
Check hot water supply at several outlets. Make sure water temperature is not too hot.
Call qualified service technician to repair leaks or address problems.
ANNUAL start-up by qualified service
technician
Obtain an Inspection and service kit (see “Replacement
parts,” page 38) before attempting to perform the annual start-up. This kit contains items that will usually
have to be replaced.
❏
Check water supply temperature at several outlets
to ensure the water temperature is acceptable for
intended use and that all temperature control devices
are functioning properly. Read page 3 and verify that
all requirements are met by the installation.
Drain the water heater if necessary
during shutdown periods
Perform the following procedures:
❏ Perform any procedures required by local codes.
❏ Verify system pressure both on domestic water and boiler water
sides.
28
❏
❏
❏
Figure 28). This will release some hot water. 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 the T&P relief valve. If T&P relief valve
weeps periodically, it may be due to thermal expansion.
Install an expansion tank if not already installed.
Follow instructions on circulator to oil it, if oil-lubricated.
Check valves, pipes and fittings for leaks.
Check function of all controls and valves (see control
manufacturer’s instructions).
Review homeowner’s maintenance responsibilities and
their frequencies, including any not listed in the following paragraphs.
1. Drain the water heater if it will be shut off and exposed
to freezing temperatures. Freezing water will expand and
may damage water heater.
a. If boiler water contains sufficient antifreeze, then only
the domestic water needs to be drained.
b. If boiler water does not contain sufficient antifreeze,
then the boiler water and the domestic water must
be drained.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Troubleshooting
Troubleshooting procedures
Follow the troubleshooting guidelines step by step. Always double-check your results. Skipping or not completing steps can lead to wrong conclusions, repeated callbacks to the job site and
unhappy customers.
Preparation for troubleshooting
Tools needed
❏ Electrical meter to measure voltage and continuity.
❏ Pressure gauge (such as Watts #276H300 test gauge).
❏ Temperature gauge.
❏ Stopwatch.
❏ Bucket — 1 gallon or larger, with volume markings.
Suggested parts to have on hand.
❏ Tank control (Thermostat) — see Replacement parts for part number.
Information needed before the service call
❏ Know the water heater model number.
❏ Know the boiler manufacturer and model number.
❏ Have the boiler manual and wiring and piping schematics readily available.
❏ Get the latest revisions from www.Weil-McLain.com.
❏ Review all manuals before leaving for the job site.
Part number 633-600-020/0918
29
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Figure 29 Typical problems and causes and page location for details
Problem
Insufficient
hot water
Excessive
domestic water
temperature
Boiler relief valve
lifting or weeping
Temperature/
pressure relief
valve lifting
or weeping
Check possible causes
1
2
3
4
Undersized water heater?
Boiler system improperly sized?
Check component parts.
Check boiler operating temperatures.
5 Check location of flow control
devices.
6 Check for air in the system.
7 Clean the boiler water system.
8 Check tank control setting.
2 Install a thermostatic mixing valve.
• Lower boiler operating tempera- 3 Install a recirculation loop.
ture.
31
1 Reduce stacking
1 Undersized expansion tank?
2 Faulty boiler expansion tank?
3 Faulty boiler relief valve?
4 Faulty boiler fill valve?
1 Undersized or missing domestic
4 High domestic water supply pres-
water side expansion tank?
2 Faulty domestic water side expansion tank?
3 Faulty T & P relief valve?
Water on the
floor near the
tank
1 Check for leaks from sources other
Top of tank or
insulation wet
1 Check for leaks from sources other
Water quality
problems
1 Water smells like “rotten eggs.”
2 Milky water.
30
Page
than the water heater.
33
33
sure?
5 Possible water hammering or pres-
sure spikes?
6 Check boiler operating temperature.
35
2 T & P relief valve lifting and dis-
charging?
3 Loose piping connections?
2 Loose piping connections?
than the water heater.
3 Discolored water from the hot
water faucet.
35
36
36
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Insufficient hot water
7 Undersized water heater?
•
There are many methods of sizing various applications, i.e. ASHRAE sizing tables or ASPE domestic water heating design
manual.
• Confirm the water demand required for the application.
•
Confirm the flow rates of the fixtures.
• For example, was the tank sized for shower heads at 2.0 gpm, while the actual heads are 5.0 gpm?
• Use a bucket and a stopwatch to determine fixture flow rates.
•
Evaluate the hot water usage pattern for a day.
• Is the peak demand unusually high for the application?
•
Has the demand for domestic hot water changed since the system was installed?
• A bathroom remodeling project with a newly installed whirlpool tub will substantially change the domestic water demand.
8 Boiler system improperly sized?
•
Can the boiler provide the required output to meet the domestic water load? Determine the boiler domestic water capacity,
GPH, by the following:
Boiler DHW capacity, GPH
=
Boiler output Btuh
Temp. rise °F x 8.33
[Temp. rise °F = Required DHW temp. °F – Incoming temp. °F]
[8.33 = Density of water (lbs/gal) x 1 Btu / lb-°F]
•
Example — A single family home with a 3.0 GPM shower fixture and a 150,000 Btuh output boiler capacity.
• The shower demand of 3.0 GPM equals 180 GPH (60 times the GPM).
• Is the boiler capacity enough to deliver this hot water flow at 115°F for an extended period? Determine the boiler capacity:
Boiler DHW capacity, GPH
•
=
150,000 Btuh
(115°F – 50°F) x 8.33
= 277 GPH
The boiler is capable of delivering 277 GPH (or 4.6 GPM) continuously, which is enough for this application.
•
Measure the BTU input to the boiler by clocking the gas meter or finding the oil flow rate based on nozzle size and pump
pressure.
•
Does the hot water system need to be wired for domestic priority? For systems in which either the storage or BTU’s available
are marginal it is recommended to wire the domestic water heater in a priority manner.
•
Is the boiler piping to the water heater properly sized to allow the required flow rate for maximum BTU transfer? The temperature differential of the boiler supply and return water should be 20°F to 30°F.
•
Is the circulator between the boiler and the water heater properly sized to provide enough flow for maximum BTU transfer?
Check the table below:
Pipe size
Flow, GPM
MBH
Pipe size
Flow, GPM
MBH
¾”
1 to 4
50 to 100
1 ½”
14 to 22
200 to 450
1”
4 to 8
100 to 180
2”
22 to 45
300 to 650
1 ¼”
8 to 14
160 to 300
Part number 633-600-020/0918
31
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Insufficient hot water (continued)
9 Check component parts.
•
Is the domestic water control functioning properly?
• Check the water heater control (requires an electrical meter).
1. Disconnect the field wiring to the water heater control terminals.
2. Turn the control knob to the highest setting — clockwise — to initiate a call for heat.
3. Check for continuity across the water heater control terminals. On a call for heat, these contacts should closed.
4. Continue checking for continuity while turning the control knob to the lowest setting — counter clockwise — to
satisfy the call for heat. The contacts should open, breaking the continuity.
5. If any of these steps fail, replace the control.
•
Is the control setting too low?
• If the control setting is too low, the boiler may not have the opportunity to deliver the maximum BTU’s required to
completely heat the entire volume of water stored in the tank.
•
During a call for heat by the water heater, does the boiler circulator begin pumping, does the zone valve open, does the boiler
fire? Check every component in the system to ensure they are properly functioning.
10 Check boiler operating temperatures.
•
If possible, increase the boiler operating temperature to 180°F or 200°F.
•
Maintain a minimal temperature in the boiler during non-heating seasons.
• A boiler typically has a higher standby loss than the indirect water heater.
• After a long standby period, the colder boiler may absorb the stored energy within the water heater during the initial call
for heat.
11 Check location of flow control devices.
•
Lab tests have shown that during long standby periods the boiler piping can act as a thermal siphon and draw stored heat
from the domestic water.
• Locate flow control devices (zone valve, spring check valves...) or heat trap loops in the boiler piping close to the water heater.
• Insulate all boiler piping to and from the water heater.
12 Check for air in the system; check water heater air vent.
•
An air-bound water heater or boiler will not circulate system water properly, resulting in a lack of heat transfer.
13 Clean the boiler water system.
32
•
A dirty boiler system can cause deposits to form on the water heater coil. This insulates the coil, reducing the heat transfer.
• Clean the boiler system per the boiler manufacturer’s instructions.
•
Install a strainer in the boiler piping on older installations or for systems likely to carry sediment.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Excessive domestic water temperature
1 Reduce stacking.
•
Excessive water temperature is usually the result of stacking within the water heater.
• Stacking is the occurrence of various water temperatures layering within the water heater with the hottest water in the
uppermost layer.
• This layering or stacking effect typically occurs during small draws of hot water (typically less than 25% of the storage
capacity) that are long enough to create a call for heat on the control, but are short enough not to deplete the stored
energy within the tank.
• Excessive stacking can occur when frequent short-to-moderate draws are taken in quick succession.
• During this condition, the temperature of the domestic water can approach the temperature of the boiler water.
•
REMEMBER — All water heaters (direct or indirect) will stack.
•
To reduce stacking within the tank:
• Reduce the boiler operating temperature to 160°F - 170°F. This will limit the maximum domestic outlet water temperature
during high stacking water usage.
2 Install a thermostatic mixing valve.
•
Installing a thermostatic mixing valve will provide uniform delivery temperature with minimal regard to water usage.
3 Install a recirculation loop.
•
Installing a properly-sized recirculation loop not only provide prompt delivery of hot water, but it will provide circulation
and mixing of the water within the tank.
Boiler relief valve lifting or weeping
1 Undersized expansion tank?
•
Insufficient allowance for expansion on the boiler side can cause the boiler pressure relief valve to lift.
•
The additional quantity of boiler water contained in the outer tank must be considered when sizing the boiler side expansion tank.
®
Part number 633-600-020/0918
AQUA PLUS
model
Boiler side volume —
gallons
35
1.6
45
1.9
55
2.2
85
2.5
105
3.5
33
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Boiler relief valve lifting or weeping
2 Faulty boiler expansion tank?
•
Is the expansion tank defective, waterlogged or improperly charged?
• Check for failed gaskets or bladders, or a faulty Schraeder valve.
• Use a tire gauge to check the charge pressure of the tank.
•
Turn the boiler limit up to a higher setting and let the system run at a higher temperature. This will simulate maximum
expansion in the boiler system.
• If the boiler relief valve lifts and/or there is a significant increase in the boiler system pressure, the expansion tank is
flooded or undersized.
3 Faulty boiler relief valve?
•
Is the boiler pressure relief valve functioning properly? Dirt and water deposits can accumulate under the valve seat.
4 Faulty boiler fill valve?
•
Is the valve filling to the correct pressure?
Temperature/pressure relief valve lifting or weeping
1 Undersized or missing domestic water side expansion tank?
•
Is there a thermal expansion tank installed on the domestic supply piping and is it properly sized?
• A thermal expansion tank is required if the domestic supply piping includes a backflow preventer or pressure reducing valve.
• Ensure the potable water expansion tank is properly sized according to the water heater volume and supply pressure.
• During long periods when there are no draws from the tank (i.e. overnight), the T&P relief valve may lift or weep due to
thermal expansion, but may function properly during normal periods of tank draws.
2 Faulty domestic water side expansion tank?
•
Is the expansion tank defective, water logged or improperly charged?
• Check for failed gaskets or bladders, or a faulty Schraeder valve.
• Use a tire gauge to check the charged pressure of the tank.
3 Faulty T & P relief valve?
•
34
Is the temperature/pressure relief valve functioning properly? Dirt and water deposits can accumulate under the valve seat.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Temperature/pressure relief valve lifting or weeping
4 High domestic water supply pressure?
•
Check the domestic supply pressure entering the water heater.
• If the pressure is over 70 psi it is recommended to install a pressure reducing valve. A thermal expansion tank is required
if a PRV is installed.
• This will prevent any pressure spikes or increases in pressure due to thermal expansion which may cause the T&P valve
to lift or weep.
5 Possible water hammering or pressure spikes?
•
Check the domestic system for possible sources of water hammering or pressure spikes.
• Some appliances such as clothes washers and dishwashers utilize fast acting valves which may cause water hammering or
pressure spikes through the domestic water system.
•
Install water hammer arrestors as required per the manufacturer’s instructions, or install flexible connectors to isolate the
tank from the domestic system.
6 Check boiler operating temperature.
•
If the boiler operating temperature is too high, stacking can occur in the water heater raising the domestic water temperature close to the boiler operating temperature. — Reduce the boiler operating temperature to 180°F. Also follow
page 33 suggestions if the problem persists.
Water on the floor near the tank
1 Check for leaks from sources other than the water heater.
•
Check for possible water seepage through foundation cracks. Did the water appear after a heavy rain?
2 Is the source of water from the T&P relief valve?
•
Place a bucket under the discharge piping of the T&P relief valve and monitor it for a day or two. This is a procedure that
can be done by the homeowner.
•
If the T&P relief valve is the source, refer to page 35 of this guide.
3 Loose piping connections?
•
Check all connections – boiler connections, domestic connections, etc.
•
Check all the boiler connections to the water heater.
• A build-up of corrosion is a sure sign of a leak.
•
Excessive force or water hammer can damage the welds where the piping connections enter the water heater tank.
• If water is leaking from around one of the tank connections, a weld may have been broken.
Contact your Weil-McLain supplier to determine how to handle the problem.
Part number 633-600-020/0918
35
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Top of tank or insulation wet
1 Check for leaks from sources other than the water heater
•
Check for possible overhead pipes leaking onto the tank.
2 Loose piping connections?
•
Check all connections – piping connections to the tank and elsewhere if the vicinity.
•
Check around valve stems.
•
A build-up of corrosion around a joint is a sure sign of a leak.
Water quality problems
1 Water smells like “rotten eggs.”
•
The most common cause of water to smell like “rotten eggs” is a non-toxic sulfate reducing bacteria.
• The bacteria usually enters into the water system through a break in the supply piping or during construction/maintenance of the supply piping.
• The bacteria survives in the water system by converting sulfate (SO4) in the water to hydrogen sulfide (H2S) gas.
• It is this gas that creates the “rotten egg” smell.
• The presence of hydrogen sulfide can also affect the taste of the water.
•
Along with the stench caused by this bacteria, black deposits that typically indicate pipe and/or fitting corrosion may also
appear in the water.
In extremely high concentrations, hydrogen sulfide gas can be toxic. However, the gas is detectable prior to reaching
harmful levels.
36
•
The bacteria will thrive in any water system under the following conditions:
• High levels of sulfur in the water.
• Activated hydrogen in the water from cathodic reactions within the tank.
• Water with little or no dissolved oxygen.
• Storing the domestic water below 130ºF.
•
Other causes of smelly water:
• Chlorides of magnesium and calcium gives water a bitter taste.
• Chloride of sodium will produce a salty tasting water.
• Sulfates above 50 ppm in the water gives the water a medicinal taste.
• Carbon dioxide in water with a low pH results in water that is fizzy.
• Iron and tannic waters will produce water with a bad taste and odor.
•
Treatment
• The treatment of this situation requires the water system to be shock-chlorinated. Depending on the severity of the bacteria within the water system, several treatments may be needed.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
Troubleshooting
— Product Manual
(continued)
Water quality problems (continued)
2 Milky water.
•
When water is initially drawn from the faucet it appears to be milky or cloudy, but it becomes clear after the water is allow
to stand for several minutes.
• This is usually an indication that the water contains high levels of soluble gases, such as oxygen, chlorine, carbon dioxide,
hydrogen sulfide or others.
• As the water system pressure increases, the amount of gas that water can hold in a solution decreases.
• When air and gases are forced out of the heated water, the problem may be evident in one or both of the following conditions:
• Gases, in the form of small bubbles, may make the water appear milky from the tap, but clear after several minutes
when those bubbles will separate.
• This is similar to the reaction that occurs as air bubbles form on the walls of a pan shortly before the water begins to boil.
• The release of dissolved gas can also create air pockets and air locks in the water system piping. This can cause spurts of
air or gases when opening the hot water faucet.
•
There is generally no cure for milky water caused by dissolve gases, although it can be reduced with aerated faucets. In some
applications the amount of air and gases precipitating out of the water will reduced in time. It should be noted that these
gases are not harmful to the end user.
3 Discolored water from the hot water faucet.
•
The water from the hot water faucet appears discolored, either rusty, brown, black or yellow.
• Because the tank is stainless steel, which is resistant to corrosion, the problem is not tank-related.
• The problem is usually a non-toxic iron-reducing bacteria that is commonly found in soil, well water, water treatment
plants and piping systems.
• The bacteria usually thrives in systems in which the soluble iron exceeds 0.2 ppm.
• The bacteria will feed on the soluble iron in the water, producing “rusty-color” water as a by-product of the feeding process.
•
Variables in which the bacteria can thrive:
• Elevated levels of iron and manganese in the water.
• Water with little or no dissolved oxygen.
• Water storage temperatures below 140ºF.
•
Items that can potentially increase the presence of the bacteria:
• Water softeners.
• Well water.
• Long periods of no water movement.
•
Treatment
• Treatment requires the water system to be shock-chlorinated.
• Depending on the severity of the bacteria within the water system, several treatments may be needed.
• Check the pH and chlorides of the water in the water heater tank and the boiler system.
• The pH must be between 6 and 8.
• Chlorides must be less than 200 ppm.
• Note the pH and chloride readings on the warranty sheet.
•
Items that can affect the pH reading:
• Water softeners.
• Water treatment plants.
• Cl ( chlorides) added, especially during the summer.
• Fl ( fluorides) added in treatment in large cities.
• Elevated levels of iron, manganese, and sulfur.
•
If the pH is high or low, this has a major effect on the metal tanks, piping and heat transfer surfaces.
Part number 633-600-020/0918
37
®
AQUA PLUS Series 2
indirect-fired water heaters
— Product Manual
Replacement parts
Figure 30 Indirect Water Heater replacement parts
Item Description
1
2
3
Control kit
(Control and sensor included)
Top plastic cap replacement kit
Bottom plastic cap replacement kit
(plastic cap and 4 screws)
Size/Model
AQUA PLUS®
Part Number
®
AQUA PLUS
Residential
35/45/55/85/105
633-600-012
35/45/55
633-500-024
85
633-500-025
105
633-500-026
35/45/55
633-500-030
85
633-500-031
105
633-500-032
All
633-500-036
35/45/55
633-500-038
85/105
633-500-039
4
Leveling leg replacement kit (4)
5
Temperature & pressure relief
valve kit
6
Fitting grommet
¾”
1”
633-500-064
633-500-037
7
Sensor cover
All
633-500-131
35, Pewter
633-500-132
45, Pewter
633-500-133
55, Pewter
633-500-134
85, Pewter
633-500-135
105, Pewter
633-500-136
8
Jacket replacement kit
9
Thermowell
All
633-500-137
–
Mixing valve kit, 1" (not shown)
All
633-500-012
38
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
®
Rating - AQUA PLUS Series 2
Figure 31 Indirect Water Heater Ratings
®
AHRI Certified Data
180°F boiler water entering | 58°F to 135°F domestic water
Model
AQUA
PLUS
Series 2
Potable
Water
Volume
Heat Source First Draw
Water Volume
Rating
Standby
Heat Loss
Continuous
Draw Rating
First Hour
Rating
Minimum Heat Source
Minimum Heat Heat
Source
Output Rate
Flow Rate Friction Loss
(Gal)
(Gal)
(Gal/hr)
Degrees F
per hour
(Gal/hr)
(Gal/hr)
(MBH)
GPM
Feet w.c.
35
29.7
1.7
21
1.0
202
223
127
14
3.8
45
39.9
1.9
35
0.8
221
256
140
14
3.4
55
54.1
2.2
50
0.6
248
298
156
14
3.5
85
81.6
2.7
67
0.5
280
347
178
14
3.5
105
110.9
3.9
72
0.4
376
448
235
14
4.9
These ratings were obtained with a heat source output rate of 234,000 Btu/h at a heat source flow rate of 14 gpm.
Other results shall be obtained under different conditions.
Part number 633-600-020/0918
39
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Ratings with 200°F boiler supply water
For water heater to achieve the rated performance below: Boiler water must be supplied to the water heater at 200°F,
and the boiler water flow rate must be no less than given in the tables below. (For AquaBalance, ECO, Evergreen,
GV90+, Ultra Gas boiler, Ultra Oil boiler or WM97+ boiler applications, with supply water at 190°F, see the ratings in the boiler manual.)
Boiler
Heating
Capacity
MBH
First Hour Rating Capacity (GPH) — Boiler Water Supply at 200°F
DO NOT exceed the boiler-side flow rate listed in “Maximum boiler-side flow rate,” page 26
DHW
temps
AQUA
PLUS
35
Boiler
Water
Min GPM &
AQUA
PLUS
45
Head Loss
Min GPM &
AQUA
PLUS
55
Head Loss
Boiler
Water
Min GPM &
AQUA
PLUS
85
Head Loss
Boiler
Water
Min GPM &
AQUA
PLUS
105
Head Loss
103
124
138
148
70
120
130
151
165
175
90
147
157
178
192
202
110
174
184
205
219
229
201
211
232
246
256
170
190
210
250
DHW 50°F to 140°F
93
150
223
237
223
8 GPM
minimum
223
@
223
1.6 ft w.c.
259
243
8 GPM
minimum
243
@
243
1.6 ft w.c.
273
286
8 GPM
minimum
302
@
302
1.6 ft w.c.
283
300
310
14 GPM
minimum
327
@
337
@
354
5.4 ft w.c.
363
302
374
417
223
243
302
374
483
350
223
243
302
374
483
400
223
243
302
374
483
450
223
243
302
374
483
500
223
243
302
374
483
50
119
129
150
164
174
70
157
166
188
201
211
90
194
203
225
239
249
110
231
241
262
276
286
268
278
299
313
323
150
170
190
210
250
DHW 50°F to 115°F
243
130
306
315
337
8 GPM
minimum
337
@
337
1.6 ft w.c.
337
352
8 GPM
minimum
363
@
363
1.6 ft w.c.
351
374
8 GPM
minimum
411
@
443
1.6 ft w.c.
7.1 ft w.c.
360
388
14 GPM
minimum
398
14 GPM
minimum
425
@
435
@
462
5.4 ft w.c.
472
337
363
443
537
547
337
363
443
551
640
350
337
363
443
551
715
400
337
363
443
551
715
450
337
363
443
551
715
500
337
363
443
551
715
300
Min GPM &
14 GPM
minimum
223
300
Boiler
Water
Head Loss
50
130
40
Boiler
Water
7.1 ft w.c.
Part number 633-600-020/0918
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Ratings with 190°F boiler supply water
For water heater to achieve the rated performance below: Boiler water must be supplied to the water heater at least
190°F, and the boiler water flow rate must be no less than given in the tables below.
Boiler
Heating
Capacity
MBH
First Hour Rating Capacity (GPH) — Boiler Water Supply at 190°F
DO NOT exceed the boiler-side flow rate listed in “Maximum boiler-side flow rate,” page 26
DHW
temps
AQUA
PLUS
35
Boiler
Water
Min GPM &
AQUA
PLUS
45
Head Loss
Boiler
Water
Min GPM &
AQUA
PLUS
55
Head Loss
Boiler
Water
Min GPM &
AQUA
PLUS
85
Head Loss
Boiler
Water
Min GPM &
AQUA
PLUS
105
Head Loss
103
124
138
148
70
120
130
151
165
175
90
147
157
178
192
202
110
174
184
205
219
229
201
211
232
246
256
170
190
210
250
DHW 50°F to 140°F
93
150
202
222
202
8 GPM
minimum
202
@
202
1.6 ft w.c.
259
222
8 GPM
minimum
222
@
222
1.6 ft w.c.
273
278
8 GPM
minimum
278
@
278
1.6 ft w.c.
283
300
14 GPM
minimum
310
14 GPM
minimum
327
@
337
@
343
5.4 ft w.c.
363
222
278
343
417
202
222
278
343
442
350
202
222
278
343
442
400
202
222
278
343
442
450
202
222
278
343
442
500
202
222
278
343
442
50
119
129
150
164
174
70
157
166
188
201
211
90
194
203
225
239
249
110
231
241
262
276
286
268
278
299
313
323
130
150
170
190
210
250
DHW 50°F to 115°F
202
300
306
315
311
8 GPM
minimum
311
@
311
1.6 ft w.c.
337
335
8 GPM
minimum
335
@
335
1.6 ft w.c.
351
374
8 GPM
minimum
411
@
411
1.6 ft w.c.
360
388
398
14 GPM
minimum
425
@
435
@
462
5.4 ft w.c.
472
335
411
511
547
311
335
411
511
640
350
311
335
411
511
662
400
311
335
411
511
662
450
311
335
411
511
662
500
311
335
411
511
662
Part number 633-600-020/0918
7.1 ft w.c.
14 GPM
minimum
311
300
Min GPM &
Head Loss
50
130
Boiler
Water
7.1 ft w.c.
41
®
AQUA PLUS Series 2
INDIRECT-FIRED WATER HEATERS
— Product Manual
Ratings with 180°F boiler supply water
For water heater to achieve the rated performance below: Boiler water must be supplied to the water heater at least
180°F, and the boiler water flow rate must be no less than given in the tables below.
Boiler
Heating
Capacity
MBH
First Hour Rating Capacity (GPH) — Boiler Water Supply at 180°F
DO NOT exceed the boiler-side flow rate listed in “Maximum boiler-side flow rate,” page 26
DHW
temps
AQUA
PLUS
35
Boiler
Water
Min GPM &
AQUA
PLUS
45
Head Loss
Min GPM &
AQUA
PLUS
55
Head Loss
Boiler
Water
Min GPM &
AQUA
PLUS
85
Head Loss
Boiler
Water
Min GPM &
AQUA
PLUS
105
Head Loss
103
124
138
148
70
120
130
151
165
175
90
147
157
178
192
202
110
174
184
205
219
229
181
200
232
246
256
170
190
210
250
DHW 50°F to 140°F
93
150
181
200
181
8 GPM
minimum
181
@
181
1.6 ft w.c.
252
200
8 GPM
minimum
200
@
200
1.6 ft w.c.
273
252
8 GPM
minimum
252
@
252
1.6 ft w.c.
283
300
310
14 GPM
minimum
310
@
337
@
310
5.4 ft w.c.
363
252
310
400
181
200
252
310
400
350
181
200
252
310
400
400
181
200
252
310
400
450
181
200
252
310
400
500
181
200
252
310
400
50
119
129
150
164
174
70
156
166
187
201
211
90
193
203
224
238
248
110
231
240
262
275
285
268
277
299
313
322
150
170
190
210
250
DHW 50°F to 115°F
200
130
284
307
284
8 GPM
minimum
284
@
284
1.6 ft w.c.
336
307
8 GPM
minimum
307
@
307
1.6 ft w.c.
350
373
8 GPM
minimum
378
@
378
1.6 ft w.c.
7.1 ft w.c.
360
387
14 GPM
minimum
397
14 GPM
minimum
424
@
434
@
461
5.4 ft w.c.
471
284
307
378
470
545
284
307
378
470
608
350
284
307
378
470
608
400
284
307
378
470
608
450
284
307
378
470
608
500
284
307
378
470
608
300
Min GPM &
14 GPM
minimum
181
300
Boiler
Water
Head Loss
50
130
42
Boiler
Water
7.1 ft w.c.
Part number 633-600-020/0918
®
INDIRECT-FIRED WATER HEATERS
AQUA PLUS Series 2
— Product Manual
Dimensions
®
Figure 32 Dimensions and ratings — AQUA PLUS Series 2 Indirect-fired Water Heaters
1 Boiler water inlet (see table
for size)
2 Boiler water outlet (see table
for size)
3 Cold domestic water inlet
(see table for size)
4 Hot domestic water outlet
(see table for size)
5 Electronic digital control
with adjustment knob
6 Sensor cover
7 Adjustable leg adjustment
range = 5/8” to 1¼” (add
this amount to the height
dimensions for total height
from floor)
8 Angle between boiler water
connections and domestic
water connections
9 Connection for T&P valve
(¾”) — valve supplied loose
with the water heater; field
installed
Storage
Model
AQUA
®
PLUS
Series 2
Connections
Dimensions (inches)
Shipping
weight
DHW
side
Boiler
side
DHW
In/Out
Boiler
water
In/Out
Gallons
Gallons
Inches
NPT
Inches
NPT
Inches
Inches
Inches
Inches
Inches
Inches
Pounds
35
29.7
1.7
³⁄₄
1
36³⁄₈
7⁷⁄₈
24
21⁷⁄₈
7³⁄₈
28
94
45
39.9
1.9
³⁄₄
1
46¹⁄₄
7⁷⁄₈
26
21⁷⁄₈
7³⁄₈
37⁷⁄₈
111
55
54.1
2.2
³⁄₄
1
60
7⁷⁄₈
29⁷⁄₈
21⁷⁄₈
7³⁄₈
51⁵⁄₈
122
85
81.6
2.7
1
1
59¹⁄₂
10³⁄₈
33¹⁄₄
26
8⁷⁄₈
50³⁄₈
223
105
110.4
3.9
1
1
59³⁄₄
14¹⁄₄
41³⁄₈
30
9⁷⁄₈
48⁵⁄₈
238
Part number 633-600-020/0918
A
B
C
D
E
G
(approx.)
43
®
AQUA PLUS Series 2
44
INDIRECT-FIRED WATER HEATERS
— Product Manual
Part number 633-600-020/0918
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement