Weil-McLain Aqua Plus 35 Product Manual
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Weil-McLain Aqua Plus 35 Product Manual

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®
Indirect-Fired Water Heaters
®
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 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 GL-E223-ADOC 0615

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Summary of Contents for Weil-McLain Aqua Plus 35

  • Page 1 ® Indirect-Fired Water Heaters ® 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 instructions in this manual and all other information shipped with the water heater.

  • Page 2: Table Of Contents

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Contents When servicing water heater ....3 Operating restrictions ......3 Boiler water restrictions .

  • Page 3: When Servicing Water Heater

    Maximum working pressure for tank — 150 PSIG. Water chemistry limits: This manual provides installation and hardness — less than 6 grains/gal. operation guidelines for Weil-McLain pH — above 6 and less than 8. AQUA PLUS indirect water heaters. chlorides — less than 200 ppm.

  • Page 4: Codes

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Pre-installation Codes Clearance recommendations 1. Installation must conform with instructions in this manual and, where applicable: local, state, provincial, and national codes, laws, regulations and ordinances. in Canada — B149.1 or B149.2 Installation Code.

  • Page 5: Domestic Water Piping Requirements

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Pre-installation (continued) Domestic water piping requirements 1. Install unions on all piping for easy removal of water heater. 2. Use to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe.

  • Page 6: Piping Overview

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Domestic water piping Piping overview DHW piping — If a backflow preventer, check valve, or pres- sure 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...
  • Page 7 T&P relief The anode is specially made for this water heater. Use valve. A thermal expansion tank is also required. only the anode available from Weil-McLain, as listed in Replacement parts. This symbol, where used in this manual, indicates the item is required by Massachusetts code.

  • Page 8: Maintaining Domestic Water Temperature In The Supply Piping

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Recirculation applications require recircu- 2. These branches must be balanced to prevent pipe erosion lation piping or heat-traced piping if the distance and unacceptable time delays at some fixtures. from the water heater to the furthest fixture exceeds 100 feet.
  • Page 9 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Recirculation (continued) Time lag to obtain hot water at fixture for branch lengths of 10 and 25 feet (ASPE Domestic Water Heating Design Manual) Copper pipe ½” ¾” Steel pipe ½” ¾”...

  • Page 10: Components

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Recirculation (continued) Components Recirculation piping 1. Little flow is required to maintain a temperature in the piping. 2. Size of circulator depends on minimum flow re- quirements of the tempering valve. 3.
  • Page 11 — Fig- ure 18, page 21. 1. This drawing is conceptual only. It shows representa- tive piping components and layout. Weil-McLain does not represent that this drawing meets any partic- ular mechanical or build- ing codes. The installer is...
  • Page 12 — Figure 18, page 21. 1. This drawing is conceptual only. It shows representa- tive piping components and layout. Weil-McLain does not represent that this drawing meets any partic- ular mechanical or build- ing codes. The installer is...
  • Page 13 — Figure 19, page 22. 1. This drawing is conceptual only. It shows representa- tive piping components and layout. Weil-McLain does not represent that this drawing meets any partic- ular mechanical or build- ing codes. The installer is...
  • Page 14 — Fig- ure 19, page 22. 1. This drawing is conceptual only. It shows representa- tive piping components and layout. Weil-McLain does not represent that this drawing meets any partic- ular mechanical or build- ing codes. The installer is...
  • Page 15 T-T terminals or heat de- mand connection. 1. This drawing is conceptual only. It shows representa- tive piping components and layout. Weil-McLain does not represent that this drawing meets any partic- ular mechanical or build- ing codes. The installer is...
  • Page 16 1. This drawing is conceptual only. It shows representa- tive piping components and layout. Weil-McLain does not represent that this drawing meets any partic- ular mechanical or build- ing codes. The installer is...
  • Page 17 See legend and details in Figure 12, page 16. 1. This drawing is conceptual only. It shows representa- tive piping components and layout. Weil-McLain does not represent that this drawing meets any partic- ular mechanical or build- ing codes. The installer is...
  • Page 18 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Connecting to a low-pressure steam boiler Special considerations Typical wiring for connection to low- pressure steam boiler When designing steam and domestic hot water systems, there are some key issues that must be taken into consideration during the initial de- sign phase.

  • Page 19: Filling The Piping

    Follow the instructions in “Water tive piping components 2. The boiler MUST be filled and ready to heater filling and start-up,” page 23, and layout. Weil-McLain operate before proceeding. Follow the to fill the domestic water side of the does not represent that this boiler manual to fill the boiler.

  • Page 20: Wiring Requirements

    Wiring options M8 hex nut Inspection plate bracket 1. This manual shows wiring only for use of Weil-McLain WMCR Cir- culator Zone Controller or Weil-McLain WMZV Zone Valve Zone Controller. 2. Other wiring methods may be acceptable and are left to the installer.
  • Page 21 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Wiring — zoning with circulators Typical wiring — zoning with circulators — DHW priority with Weil-McLain WMCR Circulator Zone Controller Notes Also refer to the WMCR manual and Weil-McLain Boiler Zone Wiring Guide for further details.
  • Page 22 AQUA PLUS INDIRECT FIRED WATER HEATERS Wiring — zoning with zone valves Typical wiring — zoning with zone valves — DHW priority with Weil-McLain WMZV Zone Valve Zone Controller Notes Also refer to the WMZV manual and Weil-McLain Boiler Zone Wiring Guide for further details.

  • Page 23: Boiler Water Restrictions

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Water heater filling and start-up Start-up checklist The installation and water chemistry must meet the ❏ requirements below. Failure to comply could result in Verify that T&P relief valve is properly installed damage to the water heater, causing possible severe and piped as directed in this manual and per local personal injury, death or substantial property damage.

  • Page 24: Setting The Thermostat

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS 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.

  • Page 25: Annual Start-Up By Qualified Service Technician

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Water heater maintenance Boiler water — read and comply with all requirements under T&P valve operation “Boiler water restrictions,” page 3. Water from opened drain valves, unions and other connec- Before operating the T&P relief tions may be extremely hot.

  • Page 26: Inspect Anode And Water Heater Interior

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Water heater maintenance (continued) Inspection hatch assembly (hatch cover shown transparent) The purpose of the is to reduce the damaging effects of aggressive water on the wa- ter heater. Aggressive water will cause the anode to erode.

  • Page 27: Troubleshooting Procedures

    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 GL-E223-ADOC 0615...

  • Page 28: Troubleshooting

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) Typical problems and causes and page location for details Problem Check possible causes Page Undersized water heater? Check location of flow control devices. Boiler system improperly sized? Insufficient Check for air in the system. Check component parts.
  • Page 29 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) Insufficient hot water 1 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.
  • Page 30 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) Insufficient hot water (continued) Is the circulator between the boiler and the water heater properly sized to provide enough flow for maxi- mum BTU transfer? Check the table below: ¾”...
  • Page 31 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) Insufficient hot water (continued) 4 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.
  • Page 32 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS 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.
  • Page 33 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) 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.
  • Page 34 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) 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.
  • Page 35 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. 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.
  • Page 36 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) Rapid decay of magnesium anode 1 Anodes last less than two years The purpose of the is to reduce the damaging effects of aggressive water on the water heater. Aggressive water will cause the anode to erode. The anode must be inspected at least annually to determine whether a new anode should be installed.
  • Page 37 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) 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.
  • Page 38 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Troubleshooting (continued) Water quality problems (continued) 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.

  • Page 39: Replacement Parts

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS Replacement parts Water heater replacement parts Magnesium anode replacement kit 35/45/55/85 633-500-014 (includes anode, o-ring, insulating 633-500-016 washer and brass bushing) Aqua PLUS Residential 633-500-020 (35/45/55/85) Thermostat repair kit Aqua PLUS Commercial 633-500-021 (105)

  • Page 40: Ahri Ratings

    — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS ® AHRI ratings AQUA Minimum Minimum Heat First Hour Continuous Heat Source First Draw Standby Potable Heat Output Heat Source Source Rating Draw Rating Friction Loss Rating Loss Volume Rate Flow Rate Volume Degrees F (Gal/hr)
  • Page 41 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS 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, Ultra Ultra and the boiler water flow rate must be no less than given in the tables below. (For Gas boiler, Oil boiler or GV90+ boiler applications, with supply water at 190°F, see the ratings in the boiler manual.)
  • Page 42 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS 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 First Hour Rating Capacity (GPH) —...
  • Page 43 — Product Manual AQUA PLUS INDIRECT FIRED WATER HEATERS 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 First Hour Rating Capacity (GPH) —...
  • Page 44 Inspection hatch with thermostat adjustment knob Magnesium anode (use only the anode supplied by Weil-McLain) Adjustable leg adjustment range = 5/8” to 1¼” (add this amount to the height dimensions for total height from floor) Angle between boiler water...

This manual is also suitable for:

Aqua plus 45Aqua plus 85Aqua plus 105Aqua plus 55

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