Weil-McLain 633-600-002 Install Instructions

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Page 1

Series 2

Indirect-Fired Water Heaters

Product Manual

• Installation

• Startup

• Maintenance

• 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 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Contents

Please read before proceeding 3

When servicing water heater . . . . . . . . . . . . . . . . . . . . 3

Operating restrictions . . . . . . . . . . . . . . . . . . . . . . . .3

Boiler water restrictions . . . . . . . . . . . . . . . . . . . . . . . 3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pre-installation 4

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Code restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Water heater placement . . . . . . . . . . . . . . . . . . . . . . .4

Install levelling legs . . . . . . . . . . . . . . . . . . . . . . . . . 4

Domestic water piping requirements. . . . . . . . . . . . . . . . 5

Water heater operating restrictions. . . . . . . . . . . . . . . . . 5

Boiler water restrictions . . . . . . . . . . . . . . . . . . . . . . . 5

Hot Water Can Scald! . . . . . . . . . . . . . . . . . . . . . . . . 5

Domestic water piping 6

Piping overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Recirculation 8

Maintaining domestic water temperature in the supply piping . 8

Time delay at ﬁxtures . . . . . . . . . . . . . . . . . . . . . . . . 8

Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Components required . . . . . . . . . . . . . . . . . . . . . . . .8

Connecting to the water heater . . . . . . . . . . . . . . . . . . .8

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Potential problems . . . . . . . . . . . . . . . . . . . . . . . . . 10

Wiring — zoning with circulators 23

Wiring — zoning with zone valves 23

Mounting and wiring the Control - New Installations 24

Setting the Thermostat Control 25

Water heater ﬁlling and start-up 26

Boiler water restrictions . . . . . . . . . . . . . . . . . . . . . . 26

Maximum boiler-side ﬂow rate . . . . . . . . . . . . . . . . . . 26

Filling the domestic water tank . . . . . . . . . . . . . . . . . . 26

Start-up and operation . . . . . . . . . . . . . . . . . . . . . . 26

Start-up checklist . . . . . . . . . . . . . . . . . . . . . . . . . 26

Water heater temperature adjustment 27

Setting the thermostat . . . . . . . . . . . . . . . . . . . . . . . 27

Hot Water Can Scald! . . . . . . . . . . . . . . . . . . . . . . . 27

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

Boiler-side piping 11

Connecting to a low-pressure steam boiler 18

Filling the piping. . . . . . . . . . . . . . . . . . . . . . . . . . 19

Boiler-side wiring and controls 20

Wiring requirements. . . . . . . . . . . . . . . . . . . . . . . . 20

Circulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Zone Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Wiring to the water heater. . . . . . . . . . . . . . . . . . . . . 20

Wiring options . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Use domestic priority . . . . . . . . . . . . . . . . . . . . . . . 20

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

Part number 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Please read before proceeding

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 installa-

tion, 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.

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.

Failure to adhere to the guidelines on this page can

result in severe personal injury, death or substantial property damage.

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

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow water heater to cool before performing maintenance.

Operating restrictions

• 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

• 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 petroleum-

based antifreeze. Do not use any undiluted antifreeze.

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 633-600-020/0118

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.

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Pre-installation

Codes

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.

Figure 1 Clearance recommendations

Recommended clearances

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.

Uniform Plumbing Code

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 op-

erating 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.

Clearance to combustible materials

1. Provide at least ½” clearance between all hot water pipes and combustible materials.

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. Carefully tip the water heater onto its side.

2. Screw the four levelling legs into the base.

3. Return the water heater to the upright position and set in place.

4. Adjust the legs as necessary to level the water heater.

Part number 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Pre-installation

(continued)

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. 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 the potable water distribution system if certain minimum water temperatures are not maintained. Contact your local health department for more information.

legionella pneumophila, can form in

Do not plug the

Hot Water Can Scald!

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

Boiler water restrictions

1. Read the WARNINGS under “Boiler water restrictions,” page 3.

• 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.

• 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 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Domestic water piping

Piping overview

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.

Figure 2 DHW 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 applica-

tions 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

35 45 55 85

DHW in/out

¾ 1 ¾ ¾ 1 ¾ ¾ 1 ¾

1 1 ¾

Boiler water in/out

Recirculation

tapping

105

1 1 ¾

Part number 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Domestic water piping

(continued)

LEGEND for Figure 2, page 6

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.

This symbol indicates the item is optional, unless

required by applicable codes.

Domestic cold water inlet connection — see Fig-

ure3,page6 for size

2 Domestic hot water outlet connection — see Fig-

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

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.

Temperature - Electronic Thermostat

12 Mixing valve — — RECOMMENDED

• See Replacement parts for thermostatic mixing valves available from Weil-McLain.

Domestic cold water supply

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.

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) —

6 Drain valve — provided by installer

• Install a drain valve on the DHW inlet to the water heater as shown.

Piping from drain valve

• Pipe from drain to ﬂoor drain, if available.

T&P valve connection

9 T&P relief valve — supplied with water heater

• 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.

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.

17 Isolation valves

18 Thermal expansion tank —

• REQUIRED if cold water line is equipped with a backﬂow preventer or pressure reducing valve — see EXPANSION

T ANK WARNING

Shock arrester —

on page 6.

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.

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.

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.

Part number 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Recirculation

Massachusetts code applications require recircu-

lation 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.

Time delay at ﬁxtures

1. Figure 5, 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. 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 4, 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.

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.

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.

4. You can use Figure 5 as a guide to determining the location of circulation return lines relative to ﬁxtures.

Balancing

1. When multiple branches are connected to the supply piping, each branch must be connected to the recirculation system.

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 4, page 9.

b. Check local codes for specific installation require-

ments.

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. 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.

Connecting to the water heater

1. Install the domestic water components as shown in Figure 2, page 6.

2. See Figure 6, page 10 for the piping required to the water heater.

— Continued on page 10 —

Part number 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Recirculation

Figure 5 Time lag to obtain hot water at ﬁxture for branch lengths of 10 and 25 feet (ASPE

Domestic Water Heating Design Manual)

(continued)

Time in seconds required to get hot water at ﬁxture (from ASPE)

Fixture ﬂow rate (GPM) - 0.5 1.5 2.5 4.0 Piping length (feet) - 10 25 10 25 10 25 10 25

Copper pipe ½” 25 63 8 21 5 13 3 8

¾” 48 119 16 40 10 24 6 15

Steel pipe ½” 63 157 21 52 13 31 8 20

¾” 91 228 30 76 18 46 11 28

CPVC pipe 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 4 Recirculation components

Part number 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Recirculation

(continued)

Components

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.

Figure 6 Recirculation piping

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 pres-

sure 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.

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 633-600-020/0118

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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 / select ion of all hardware shown on this diagram.

2. See boiler manual for spe-

ciﬁc details on installing the boiler.

Part number 633-600-020/0118

Recommended ﬂow rate and minimum boiler-side pipe size

Heater model GPM Pipe size Heater model GPM Pipe size

35 45 55

8 1” 8 1” 8 1”

105

Requires 1¼”x1” reducers at water heater

14 1¼” * 14 1¼” *

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Boiler-side piping

Figure 8 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.

(continued)

1. This drawing is conceptual

2. See boiler manual for spe-

ciﬁc details on installing the boiler.

Recommended ﬂow rate and minimum boiler-side pipe size

Heater model GPM Pipe size Heater model GPM Pipe size

35 45 55

8 1” 8 1” 8 1”

105

Requires 1¼”x1” reducers at water heater

14 1¼” * 14 1¼” *

Part number 633-600-020/0118

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AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Boiler-side piping

Figure 9 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.

(continued)

1. This drawing is conceptual

2. See boiler manual for spe-

ciﬁc details on installing the boiler.

Part number 633-600-020/0118

Recommended ﬂow rate and minimum boiler-side pipe size

Heater model GPM Pipe size Heater model GPM Pipe size

35 45 55

8 1” 8 1” 8 1”

105

Requires 1¼”x1” reducers at water heater

14 1¼” * 14 1¼” *

Page 14

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Boiler-side piping

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.

(continued)

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.

Recommended ﬂow rate and minimum boiler-side pipe size

Heater model GPM Pipe size Heater model GPM Pipe size

35 45 55

8 1” 8 1” 8 1”

105

Requires 1¼”x1” reducers at water heater

14 1¼” * 14 1¼” *

Part number 633-600-020/0118

Page 15

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Boiler-side piping

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 thermostat wires to boiler’s T-T terminals or heat demand connection.

(continued)

2. See boiler manual for speciﬁc details on installing the boiler.

Part number 633-600-020/0118

Recommended ﬂow rate and minimum boiler-side pipe size

Heater model GPM Pipe size Heater model GPM Pipe size

35 45 55

8 1” 8 1” 8 1”

105

Requires 1¼”x1” reducers at water heater

14 1¼” * 14 1¼” *

Page 16

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Boiler-side piping

Figure 12 Multiple water heaters — domestic water piping

Failure to install automatic mixing valve where recom-

mended can result in severe personal injury or death.

(continued)

2. Wire water heater thermostats in series when connecting to boiler controller or boiler T-T terminals.

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.

Figure 13 Alternate methods of revers-return piping and Easy-Fit® Manifold detail

Part number 633-600-020/0118

Page 17

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Boiler-side piping

Figure 14 Multiple water heaters and dedicated multiple boilers — boiler water piping

Notes

• See legend and details in Figure 12, page 16.

(continued)

1. This drawing is conceptual

2. See boiler manual for spe-

ciﬁc details on installing the boiler.

Part number 633-600-020/0118

Page 18

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.

Figure 15 Typical wiring for connection to low-

pressure 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 boil-

er’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 633-600-020/0118

Page 19

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

2. See boiler manual for spe-

ciﬁc details on installing the boiler.

Filling the piping

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 1 Close isolation valves 5 and 6 to isolate

the boiler.

Step 2 Close valve 3 and open valve 4. Con-

nect a cold water supply hose to valve 3. Connect a hose from valve 4 to a drainable location.

Step 3 Close valve 10. Open valve 7. 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 5 Close valve 7. Then open valve 10. 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 9 Open isolation valves 5 and 6. Make

sure the boiler water level is correct per the boiler manual.

Step 10 Start the boiler per instructions given

in the boiler manual. Allow boiler to begin steaming.

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 12 Continue checking under varying

DHW demand conditions to ensure system will operate as required.

Part number 633-600-020/0118

Page 20

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

24 VAC

Input

To Boil er Cont rol

AcuTemp

2000WM

thermostat

AquaBalance boiler

Control terminals

500075-60

Boiler-side wiring and controls

Electrical shock hazard — Can cause severe

personal injury, death or substantial property damage. Disconnect power before installing and / or servicing.

Wiring requirements

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

• U.S.A. — National Electrical Code 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.

Figure 17 Wiring the control “General Connection”

Circulators

Size priority relay for total amp draw of all circulators.

Zone Valves

Size transformer for maximum load of all zone valves.

Wiring to the water heater

1. Field connections to the water heater thermostat are for 24 VAC 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.

Wiring options

1. This manual shows wiring only for use of Weil-McLain WMCR Circulator Zone Controller or Weil-McLain WMZV Zone Valve Zone Controller.

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.

Figure 18 Wiring the control to the AquaBalance

controls will connect to the AcuTemp 2000 WM thermostat.

boiler

Part number 633-600-020/0118

Page 21

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

1 2 3 4 5

1 2 3 4

Additional limits if used (Will require manual reset)

Additional limits if used (Control will automatically reset)

P13

P11

P10

P12

Display/interface

panel

Flue temp.

sensor

Heat exchanger

outlet temp.

sensor

Red

Orange

Gray

Black

Factory jumpers (remove if using limits)

Outdoor temp. sensor (if used)

Low water cutoff (if used)

AcuTemp

2000WM

thermostat

ECO boiler

Control terminals

500075-62

24 VAC

Input

To Zone

Boiler

Contro l

For replacement order part number 381-330-020 Control Part Number 511-330-279

WARNING

EXPLOSION HA ZARD CAN CAUSE SER IOUS INJU RY OR DEATH This device can malfunction if it

gets wet. Never attempt to use this device if it has been wet –

REPLACE IT !

NOTICE

Please refer to boiler manual for wiring instructions. Use copper

conductor only suitable for a minimum 105° C wire or equivalent.

CAUTION

Risk of ELECTRI CAL SHOCK - more than one disconnect

switch maybe required to de-energize the device for servicing.

White

P10

P13

P11

P12

P14

P15

P16

REMOTE

SENSE

AcuTemp 2000WM

thermostat

Evergreen boiler

Control terminals

500075-63

1 2 3 4 5

1 2 3 4

1 2 3

1 2 3 4 5 6

P15

P14

P13

P11

P10

P12

Red

Blue

Orange

Gray

Black

Common

Factory jumpers (remove if using limits)

Boiler-to Boiler Out (multiple boilers only)

Boiler-to Boiler In (multiple boilers only)

Fuse 3-amp 120vac

Y Y

W R

R W

24 VAC

Input

To Zone

Boiler

Contro l

Boiler-side wiring and controls

Figure 19 Wiring the control to the CGa (1135-05/606),

CGi (1135-615), and the EG Water (1135-605) boiler controls will connect to the AcuTemp 2000WM thermostat.

Figure 20 Wiring the control to the ECO (1176-120/121)

boiler controls will connect to the AcuTemp 2000WM thermostat.

(continued)

Figure 21 Wiring the control to the Evergreen (1176-160) and SlimFit 550-750 (1176-170) boiler controls will connect to

the AcuTemp 2000WM thermostat.

Part number 633-600-020/0118

Page 22

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

To thermostat

Air pressure

switch

500075-64

White hose

Red hose

AcuTemp 2000WM

thermostat

GV90+ boiler

Control terminals

24 VAC

Input

Boil er

Cont rol

Ground

Screw

P16

1234567 1234567

1 2 3 4 5

1 2 3 4

1 2 3

1 2 3 4 5 6

120V

Call for heat demand 2 (Default for thermostat)

Call for heat demand 3.

Modulating input (0 – 10 VDC)

System supply temperature sensor

Additional limits if used (Will require manual reset)

Additional limits if used (Control will automatically reset)

Low water cutoff (if used)

P15

P14

P13

P11

P10

P12

Display/interface

panel

Flue temp.

sensor

Heat exchanger

outlet temp.

sensor

Heat exchanger

inlet temp.

sensor

Gas

valve

Red

Blue

Orange

Gray

Black

White

16-pin

connector

(through cabinet)

Common

24V

Factory jumpers (remove if using limits)

System return temperature sensor

AcuTemp

2000WM thermostat

Ultra boiler

Control terminals

500075-66

24 VAC

Input

To Zone

Boiler

Contro l

Boiler-side wiring and controls

Figure 22 Wiring the control to the GV90+ (1135-700)

boiler controls will connect to the AcuTemp 2000WM thermostat.

Figure 24 Wiring the control to the Ultra (1176-100) boiler

controls will connect to the AcuTemp 2000WM thermostat.

(continued)

Figure 23 Wiring the control to the WM97+ (1176-112/113) boiler controls will connect to the AcuTemp 2000WM

thermostat.

Part number 633-600-020/0118

Page 23

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

50075-40

24 VAC

Input

To Zone

Boiler

Control

Thermostats

Circulators

Priority circulator

120VAC

Hot

Neutral

Grd

Control Port

Electronic

Fuse

WMCR-4

Circulator Zone Controller

Weil-McLain Michigan City, IN

120 VAC Circulators

Priority Zone

Zone 2

Zone 3

Zone 4

120 VAC IN

Isolated

Switch

Priority ON

X–X

ZR/ZC

Zone 1

THERMOSTATS

1234

234

Zone 2 Zone 3

Zone 4

Zone 2 Zone 3 Zone 4

Common

24 V @ 1 VA

To Expansion

Module

OUT

LLLNNN

To boiler T–T

Water Heater

AcuTemp

2000WM thermostat

Boiler-side wiring and controls

Figure 25 Typical wiring — zoning with circulators — DHW priority with Weil-McLain

WMCR Circulator Zone Controller

1. These drawings are concep-

tual 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.

System piping

• Figure 7, page 11

• Figure 8, page 12

(continued)

Notes

• Also refer to the WMZV manual and Weil-McLain

Boiler Zone Wiring Guide for further details.

• Refer to Wiring requirements on page 20.

System piping

• Figure 9, page 13

• Figure 10, page 14

Install all zone valves per valve manufacturer’s instructions.

Part number 633-600-020/0118

Figure 26 Typical wiring — zoning with zone valves — DHW priority with Weil-McLain

WMZV Zone Valve Zone Controller

AcuTemp

To Zone

Boiler

Control

Connect 120VAC power leads to transformer black and white leads.

2000WM thermostat

24 VAC

Input

To circulator or boilerT–T

terminals

24 VAC

COM

24 VACEND SW 1

24 VAC constant to 5-wire

zone

valves

Thermostat

zone 2

Thermostat

zone 3

T T

X-X ON

55XX

Priority

zone

switch

OFF

1234 1234 1234 1234

To zone 2

zone valve

To priority

zone valve

Zone 3Zone 2Priority

To zone 3

zone valve

Thermostat

zone 4

T TT TT T

Zone 4

To zone 4

zone valve

50075-41

Zone Valve Controller

WMZV-4

Weil-McLain

Michigan City, IN

Page 24

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.

2. Route the sensor wire through the opening in the rear of the control.

4. Insert the sensor wire into the channel in the back 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.

Refer to “Boiler-side wiring and controls” on pages 20 - 23 for wiring instructions.

6. Add a third screw through the top of the control. Reinstall control cover once wiring connections are made and the control is mounted.

Part number 633-600-020/0118

Page 25

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Setting the Thermostat 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.

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.

Calling for Heat Standby

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 tem-

perature setting.

3 Setting the Temperature / Differential.

The differential does not need to be set. The thermostat’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 633-600-020/0118

Page 26

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 petroleum-

based 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 AQ UA PLUS

• Models A QU A PLUS

-32, 42 and 52 - do not exceed 12 GPM.

-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 con-



nected to domestic water system.

Verify that supply and return piping from boiler is cor-



rectly connected to water heater.

Check all ﬁttings and piping for leaks.



Verify that all wiring is installed correctly.



Set water heater thermostat 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

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.

• Water Heater Start-Up

• Adjusting Water Heater Temperature

• Water Heater Maintenance

Part number 633-600-020/0118

Page 27

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 thermostat accordingly.

• Always recheck temperature after adjusting thermostat.

• 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 thermostat 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, includ-

ing

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 thermostat

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

2. Turn thermostat knob clockwise to increase water temperature.

3. Turn thermostat knob counter-clockwise to reduce water temperature.

4. When decreasing temperature setting, the stored hot water must be drawn off before checking temperature at faucet.

5. 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.

6. When adjusting thermostat, be sure boiler limit control is set a minimum 20°F higher.

7. See information packed with thermostat for more instructions.

Figure 27 Water heater digital temperature control

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

• 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.

• 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.

Part number 633-600-020/0118

Page 28

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.

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.

ATTENTION USER!

Have the water heater serviced at least once

annually

Follow the maintenance procedures below at least

monthly.

Read “Water heater temperature adjustment,”

page 27.

Failure to comply with the above can result in se-

vere personal injury, death or substantial property damage.

by a qualiﬁed service technician.

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.

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.

Perform the following procedures:

Perform any procedures required by local codes.



Verify system pressure both on domestic water and boiler water



sides.

Figure 28 T&P valve operation

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.

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.

Manually operate T&P relief valve at least once a year (see



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.

Drain the water heater if necessary during shutdown periods

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 633-600-020/0118

Page 29

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. Skip-

ping 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 thermostat (Thermostat) — see Replacement parts for part number.



Inspection and service kit — 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 633-600-020/0118

Page 30

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

Figure 29 Typical problems and causes and page location for details

Problem Check possible causes Page

Insufﬁcient hot water

Excessive domestic water temperature

Boiler relief valve lifting or weeping

(continued)

1 Undersized water heater? 2 Boiler system improperly sized? 3 Check component parts. 4 Check boiler operating tempera-

tures.

1 Reduce stacking

• Lower boiler operating temperature.

1 Undersized expansion tank? 2 Faulty boiler expansion tank? 3 Faulty boiler relief valve?

5 Check location of ﬂow control

devices.

6 Check for air in the system. 7 Clean the boiler water system. 8 Check tank thermostat setting.

2 Install a thermostatic mixing valve. 3 Install a recirculation loop.

4 Faulty boiler ﬁll valve?

Temperature/ pressure relief valve lifting or weeping

Water on the ﬂoor near the tank

Top of tank or insulation wet

Water quality problems

1 Undersized or missing domestic

water side expansion tank?

2 Faulty domestic water side expan-

sion tank?

3 Faulty T & P relief valve?

1 Check for leaks from sources other

than the water heater.

1 Check for leaks from sources other

than the water heater.

1 Water smells like “rotten eggs.” 2 Milky water.

4 High domestic water supply pres-

sure?

5 Possible water hammering or pres-

sure spikes?

6 Check boiler operating tempera-

ture.

2 T & P relief valve lifting and dis-

charging?

3 Loose piping connections?

2 Loose piping connections?

3 Discolored water from the hot

water faucet.

Part number 633-600-020/0118

Page 31

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

(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 =

[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 =

(115°F – 50°F) x 8.33

• 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:

Boiler output Btuh

Temp. rise °F x 8.33

150,000 Btuh

= 277 GPH

Part number 633-600-020/0118

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

Page 32

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

(continued)

Insufﬁcient hot water (continued)

9 Check component parts.

• Is the domestic water thermostat functioning properly?

• Check the water heater thermostat (requires an electrical meter).

1. Disconnect the ﬁeld wiring to the water heater thermostat terminals.

2. Turn the thermostat knob to the highest setting — clockwise — to initiate a call for heat.

3. Check for continuity across the water heater thermostat terminals. On a call for heat, these contacts should closed.

4. Continue checking for continuity while turning the thermostat 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 thermostat.

• Is the thermostat setting too low?

• If the thermostat 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.

• 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 633-600-020/0118

Page 33

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

(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 thermostat, 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.

AQUA PLUS

model

Boiler side volume —

gallons

Part number 633-600-020/0118

35 1.6 45 1.9 55 2.2 85 2.5

105 3.5

Page 34

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

(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?

• Is the temperature/pressure relief valve functioning properly? Dirt and water deposits can accumulate under the valve seat.

Part number 633-600-020/0118

Page 35

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

(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 tem-

perature 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 633-600-020/0118

Page 36

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

(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.

• 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 bac-

teria within the water system, several treatments may be needed.

Part number 633-600-020/0118

Page 37

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Troubleshooting

(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 633-600-020/0118

Page 38

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Replacement parts

Figure 30 Indirect Water Heater replacement parts

Item Description

Thermostat repair kit

(Control and sensor included)

2 T op plastic cap replacement kit

Bottom plastic cap replacement kit

(plastic cap and 4 screws)

4 Leveling leg replacement kit (4) All 633-500-036

emperature & pressure relief

valve kit

6 Fitting grommet

Size/Model

AQUA PLUS

AQUA PLUS®

Residential

35/45/55/

85/105

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

35/45/55 633-500-038

85/105 633-500-039

¾”

1”

Part Number

633-600-012

633-500-064 633-500-037

7 Sensor cover All 633-500-131

35, Pewter 633-500-132 45, Pewter 633-500-133

8 Jacket replacement kit

9 Thermowell All 633-500-137 – Mixing valve kit, 1" (not shown) All 633-500-012

55, Pewter 633-500-134 85, Pewter 633-500-135

105, Pewter 633-500-136

Part number 633-600-020/0118

Page 39

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

105

Potable

Water

Volume

(Gal) (Gal) (Gal/hr)

Heat Source

Water Volume

First Draw

Rating

Standby

Heat Loss

Degrees F

per hour

Continuous Draw Rating

(Gal/hr) (Gal/hr) (MBH) GPM Feet w.c.

First Hour

Rating

Minimum Heat

Output Rate

Minimum

Heat Source

Flow Rate

Heat Source Friction Loss

29.7 1.7 21 1.0 202 223 127 14 3.8

39.9 1.9 35 0.8 221 256 140 14 3.4

54.1 2.2 50 0.6 248 298 156 14 3.5

81.6 2.7 67 0.5 280 347 178 14 3.5

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.

Part number 633-600-020/0118

Other results shall be obtained under different conditions.

Page 40

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

50 70

90 110 130 150 170 190 210 250 300 350 400 450 500

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

93 120 130 151 165 175 147 157 178 192 202 174 184 205 219 229 201 211 232 246 256 223 237 259 273 283 223 243 286 300 310 223 243 302 327 337 223 243 302 354 363 223 243 302 374 417 223 243 302 374 483

DHW 50°F to 140°F

223 243 302 374 483 223 243 302 374 483 223 243 302 374 483 223 243 302 374 483 119 157 166 188 201 211 194 203 225 239 249 231 241 262 276 286 268 278 299 313 323 306 315 337 351 360 337 352 374 388 398 337 363 411 425 435 337 363 443 462 472 337 363 443 537 547 337 363 443 551 640

DHW 50°F to 115°F

337 363 443 551 715 337 363 443 551 715 337 363 443 551 715 337 363 443 551 715

Boiler Water

Min GPM &

Head Loss

8 GPM

minimum

1.6 ft w.c.

8 GPM

minimum

1.6 ft w.c.

AQUA

PLUS

103

Boiler Water

Min GPM &

Head Loss

AQUA

PLUS

124

8 GPM

minimum

1.6 ft w.c.

129

150

8 GPM

minimum

1.6 ft w.c.

Boiler Water

Min GPM &

Head Loss

8 GPM

minimum

1.6 ft w.c.

8 GPM

minimum

1.6 ft w.c.

AQUA

PLUS

138

164

Boiler Water

Min GPM &

Head Loss

14 GPM

minimum

5.4 ft w.c.

14 GPM

minimum

5.4 ft w.c.

AQUA

PLUS

105

148

174

Boiler Water

Min GPM &

Head Loss

14 GPM

minimum

7.1 ft w.c.

14 GPM

minimum

7.1 ft w.c.

Part number 633-600-020/0118

Page 41

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

50 70

90 110 130 150 170 190 210 250 300 350 400 450 500

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

93 120 130 151 165 175 147 157 178 192 202 174 184 205 219 229 201 211 232 246 256 202 222 259 273 283 202 222 278 300 310 202 222 278 327 337 202 222 278 343 363 202 222 278 343 417 202 222 278 343 442

DHW 50°F to 140°F

202 222 278 343 442 202 222 278 343 442 202 222 278 343 442 202 222 278 343 442 119 157 166 188 201 211 194 203 225 239 249 231 241 262 276 286 268 278 299 313 323 306 315 337 351 360 311 335 374 388 398 311 335 411 425 435 311 335 411 462 472 311 335 411 511 547 311 335 411 511 640

DHW 50°F to 115°F

311 335 411 511 662 311 335 411 511 662 311 335 411 511 662 311 335 411 511 662

Boiler Water

Min GPM &

Head Loss

8 GPM

minimum

1.6 ft w.c.

8 GPM

minimum

1.6 ft w.c.

AQUA

PLUS

103

Boiler Water

Min GPM &

Head Loss

AQUA

PLUS

124

8 GPM

minimum

1.6 ft w.c.

129

150

8 GPM

minimum

1.6 ft w.c.

Boiler Water

Min GPM &

Head Loss

8 GPM

minimum

1.6 ft w.c.

8 GPM

minimum

1.6 ft w.c.

AQUA

PLUS

138

164

Boiler Water

Min GPM &

Head Loss

14 GPM

minimum

5.4 ft w.c.

14 GPM

minimum

5.4 ft w.c.

AQUA

PLUS

105

148

174

Boiler Water

Min GPM &

Head Loss

14 GPM

minimum

7.1 ft w.c.

14 GPM

minimum

7.1 ft w.c.

Part number 633-600-020/0118

Page 42

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

50 70

90 110 130 150 170 190 210 250 300 350 400 450 500

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

93 120 130 151 165 175 147 157 178 192 202 174 184 205 219 229 181 200 232 246 256 181 200 252 273 283 181 200 252 300 310 181 200 252 310 337 181 200 252 310 363 181 200 252 310 400 181 200 252 310 400

DHW 50°F to 140°F

181 200 252 310 400 181 200 252 310 400 181 200 252 310 400 181 200 252 310 400 119 156 166 187 201 211 193 203 224 238 248 231 240 262 275 285 268 277 299 313 322 284 307 336 350 360 284 307 373 387 397 284 307 378 424 434 284 307 378 461 471 284 307 378 470 545 284 307 378 470 608

DHW 50°F to 115°F

284 307 378 470 608 284 307 378 470 608 284 307 378 470 608 284 307 378 470 608

Boiler Water

Min GPM &

Head Loss

8 GPM

minimum

1.6 ft w.c.

8 GPM

minimum

1.6 ft w.c.

AQUA

PLUS

103

Boiler Water

Min GPM &

Head Loss

AQUA

PLUS

124

8 GPM

minimum

1.6 ft w.c.

129

150

8 GPM

minimum

1.6 ft w.c.

Boiler Water

Min GPM &

Head Loss

8 GPM

minimum

1.6 ft w.c.

8 GPM

minimum

1.6 ft w.c.

AQUA

PLUS

138

164

Boiler Water

Min GPM &

Head Loss

14 GPM

minimum

5.4 ft w.c.

14 GPM

minimum

5.4 ft w.c.

AQUA

PLUS

105

148

174

Boiler Water

Min GPM &

Head Loss

14 GPM

minimum

7.1 ft w.c.

14 GPM

minimum

7.1 ft w.c.

Part number 633-600-020/0118

Page 43

AQUA PLUS® Series 2 indirect-fired water heaters — 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 thermostat

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

Model AQUA

PLUS

Series 2

35 45 55 85

DHW

side

Gallons Gallons

29.7 1.7

39.9 1.9

54.1 2.2

81.6 2.7

Storage Connections Dimensions (inches)

Boiler

side

DHW

In/Out

Inches

NPT

Boiler

water

In/Out

Inches

NPT

C\v 1 36C\, 7M\, 24 21M\, 7C\, 28

C\v 1 46Z\v 7M\, 26 21M\, 7C\, 37M\,

C\v 1 60 7M\, 29M\, 21M\, 7C\, 51B\,

1 1 59Z\x 10C\, 33Z\v 26 8M\, 50C\,

A B C D E

Inches Inches Inches Inches Inches Inches Pounds

9 Connection for T&P valve

(¾”) — valve supplied loose with the water heater; ﬁeld installed

Shipping

weight

(approx.)

111

122

223

105

Part number 633-600-020/0118

110.4 3.9

1 1 59C\v 14Z\v 41C\, 30 9M\, 48B\,

238

Page 44

AQUA PLUS® Series 2 indirect-fired water heaters — Product Manual

Part number 633-600-020/0118