Weil-McLain GL-E223-ADOC User Manual
®
TM
Indirect-Fired Water Heaters
Product Manual
®
• Installation
• Startup
• Maintenance
• Parts
User — Read important user safety information found on page 3, page 24 and page 25. 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 instruc-
tions 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 GL-E223-ADOC 0311
AQUA PLUS 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 21
Wiring — zoning with zone valves 22
Water heater filling and start-up 23
Boiler water restrictions . . . . . . . . . . . . . . . . . . . . . . 23
Maximum boiler-side flow rate . . . . . . . . . . . . . . . . . . 23
Filling the domestic water tank . . . . . . . . . . . . . . . . . . 23
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . 23
Start-up checklist . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water heater temperature adjustment 24
Setting the thermostat . . . . . . . . . . . . . . . . . . . . . . . 24
Hot Water Can Scald! . . . . . . . . . . . . . . . . . . . . . . . 24
Water heater maintenance 25
ANNUAL start-up by qualified service technician . . . . . . . 25
Inspect anode and water heater interior . . . . . . . . . . . . . 26
Drain the water heater if necessary during shutdown periods . 26
Troubleshooting 27
Troubleshooting procedures . . . . . . . . . . . . . . . . . . . 27
Preparation for troubleshooting . . . . . . . . . . . . . . . . . 27
Replacement parts 39
AHRI ratings 40
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
2
Ratings with 200°F boiler supply water 41
Ratings with 190°F boiler supply water 42
Ratings with 180°F boiler supply water 43
Dimensions 44
Part number GL-E223-ADOC 0311
AQUA PLUS 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 GL-E223-ADOC 0311
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 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.
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.
4
Part number GL-E223-ADOC 0311
AQUA PLUS 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
3.
4. If the water heater will replace a tankless coil in the boiler, discon-
dielectric unions or couplings to protect hot and cold water
fittings from corrosion when connecting dissimilar materials such
as copper and galvanized iron pipe.
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.
nect 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
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
Hot Water Can Scald!
• Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald
and cause permanent injury.
Water heater operating restrictions
1. Read the operating limits under “Operating restrictions,” page 3.
Magnesium anode — The water heater is equipped with
a magnesium sacrificial anode. The anode may erode over
time, and should be inspected at least once annually, only
by a qualified service technician. For installations with
a likelihood of poor water conditions, the anode should
be inspected at least every six months. Failure to comply
could result in loss of protection by the anode, causing
possible severe personal injury, death or substantial
property damage due to water heater leakage.
The domestic water chloride concentration must not ex-
ceed 200 ppm. High chloride concentrations can rapidly
disintegrate the water heater’s protective anode.
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 GL-E223-ADOC 0311
5
AQUA PLUS 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 injur y, 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
Model
AQUA PLUS
35
45
55
85
105
Connections
DHW
in/out
¾ 1 ¾
¾ 1 ¾
¾ 1 ¾
1 1 ¾
1 1 ¾
(inches NPT)
Boiler water
in/out
Recirculation
tapping
6
Part number GL-E223-ADOC 0311
AQUA PLUS 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.
1
Domestic cold water inlet connection — see Figure3,page6 for size
2 Domestic hot water outlet connection — see Fig-
ure3,page6 for size
3 Domest ic recirculation connec tion — see Fig-
ure3,page6 for size
4 Boiler water inlet to coil — see Figure3,page6 for size
5 Boiler water outlet from coil — see Figure3,page6 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
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.
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.
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 adjustment knob
11
12Anode access
• The anode is specially made for this water heater. Use
only the anode available from Weil-McLain, as listed in
Replacement parts.
Mixing valve — — RECOMMENDED
13
• See Replacement parts for thermostatic mixing valves
available from Weil-McLain.
Domestic cold water supply
14
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
15
system
(when used — requires mixing valve)
16Domestic high-temperature hot water supply to
system
17Heat trap loops (12” minimum) —
18Isolation valves
19Thermal expansion tank —
• REQUIRED if cold water line is equipped with a backflow
preventer or pressure reducing valve — see EXPANSION
TANK WARNING
Shock arrester —
20
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
21
• 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
22
for Commonwealth of Massachusetts)
23Vacuum breaker —
24Pressure reducing valve —
• REQUIRED when the supply pressure is higher than
70 PSIG — A thermal expansion tank is also required.
Part number GL-E223-ADOC 0311
7
AQUA PLUS 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 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. 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.
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 4 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 5, 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 —
8
Part number GL-E223-ADOC 0311
AQUA PLUS indirect-fired water heaters — Product Manual
Recirculation
Figure 4 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 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
Steel pipe ½” 63 157 21 52 13 31 8 20
CPVC pipe ½” 64 159 21 53 13 62 8 20
NOTE: Select branch size and length for less than 31 seconds delay.
(continued)
¾” 48 119 16 40 10 24 6 15
¾” 91 228 30 76 18 46 11 28
¾” 95 238 32 79 19 48 12 30
Figure 5 Recirculation components
Part number GL-E223-ADOC 0311
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AQUA PLUS 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.
10
Part number GL-E223-ADOC 0311
AQUA PLUS 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 18, page 21.
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
35
45
55
GPM
Pipe
size
8 1”
8 1”
8 1”
Heater
model
85
105
Requires 1¼”x1” reducers at water heater
GPM
14 1¼” *
14 1¼” *
Pipe
size
GV90+ or Ultra gas boilers:
DO NOT apply the drawings in
this manual. Refer only to the
boiler manual.
Part number GL-E223-ADOC 0311
11
AQUA PLUS indirect-fired water heaters — Product Manual
Boiler-side piping
(continued)
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 18, page 21.
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
35
45
55
GPM
Pipe
size
8 1”
8 1”
8 1”
Heater
model
85
105
Requires 1¼”x1” reducers at water heater
GPM
14 1¼” *
14 1¼” *
Pipe
size
GV90+ or Ultra gas boilers:
DO NOT apply the drawings in
this manual. Refer only to the
boiler manual.
Part number GL-E223-ADOC 0311
AQUA PLUS indirect-fired water heaters — Product Manual
Boiler-side piping
(continued)
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 19, page 22.
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 GL-E223-ADOC 0311
Recommended flow rate and minimum boiler-side pipe size
Heater
model
35
45
55
GPM
Pipe
size
8 1”
8 1”
8 1”
Heater
model
85
105
Requires 1¼”x1” reducers at water heater
GPM
14 1¼” *
14 1¼” *
Pipe
size
GV90+ or Ultra gas boilers:
DO NOT apply the drawings in
this manual. Refer only to the
boiler manual.
13
AQUA PLUS indirect-fired water heaters — Product Manual
Boiler-side piping
(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 19, page 22.
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
35
45
55
GPM
Pipe
size
8 1”
8 1”
8 1”
Heater
model
85
105
Requires 1¼”x1” reducers at water heater
GPM
14 1¼” *
14 1¼” *
Pipe
size
GV90+ or Ultra gas boilers:
DO NOT apply the drawings in
this manual. Refer only to the
boiler manual.
Part number GL-E223-ADOC 0311
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