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

Aqua plus series indirect-fired water heaters
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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 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.
Indirect-Fired Water Heaters
• Installation
• Startup
TM
• Maintenance
• Parts
Part number GL-E223-ADOC 0614

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Summary of Contents for Weil-McLain Aqua Plus 35

  • Page 1 ® Indirect-Fired Water Heaters Product Manual • Installation • Maintenance • Startup • 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.

  • Page 2: Table Of Contents

    AQUA PLUS — Product Manual indirect fired water heaters Contents Please read before proceeding Wiring — zoning with circulators When servicing water heater ....3 Operating restrictions .

  • Page 3: Please Read Before Proceeding

    • 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: Pre-Installation

    AQUA PLUS — Product Manual indirect fired water heaters Pre-installation Codes Figure 1 Clearance recommendations 1. Installation must conform with instructions in this manual and, where applicable: • local, state, provincial, and national codes, laws, regulations and ordinances. • in Canada — B149.1 or B149.2 Installation Code.

  • Page 5: Domestic Water Piping Requirements

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

  • Page 6: Domestic Water Piping

    AQUA PLUS — Product Manual indirect fired water heaters Domestic water piping Piping overview Figure 2 DHW piping THERMAL ExPANSIoN TANk — 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 • 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: Recirculation

    AQUA PLUS — Product Manual indirect fired water heaters Recirculation Massachusetts code 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 AQUA PLUS — Product Manual indirect fired water heaters Recirculation (continued) Figure 5 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) - Piping length (feet) - Copper pipe...

  • Page 10: Components

    AQUA PLUS — Product Manual indirect fired water heaters Recirculation (continued) Components Figure 6 Recirculation piping Circulator (Figure 6, item 1) 1. Little flow is required to maintain a temperature in the piping. 2. Size of circulator depends on minimum flow re- quirements of the tempering valve.

  • Page 11: Boiler-Side Piping

    — 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: Connecting To A Low-Pressure Steam Boiler

    AQUA PLUS — Product Manual indirect fired water heaters Connecting to a low-pressure steam boiler Special considerations Figure 15 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

    Step 7 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: Boiler-Side Wiring And Controls

    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: Wiring - Zoning With Circulators

    — Product Manual indirect fired water heaters Wiring — zoning with circulators Figure 18 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: Wiring - Zoning With Zone Valves

    — Product Manual indirect fired water heaters Wiring — zoning with zone valves Figure 19 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: Water Heater Filling And Start-Up

    AQUA PLUS — Product Manual 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: Water Heater Temperature Adjustment

    AQUA PLUS — Product Manual 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. •...

  • Page 25: Water Heater Maintenance

    AQUA PLUS — Product Manual indirect fired water heaters Water heater maintenance Boiler water — read and comply with all requirements under Figure 21 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

    AQUA PLUS — Product Manual indirect fired water heaters Water heater maintenance (continued) and their frequencies, including any not listed in the following Figure 22 Inspection hatch assembly (hatch cover paragraphs. shown transparent) magnesium anode The purpose of the is to reduce the damaging effects of aggressive water on the wa- ter heater.

  • Page 27: Troubleshooting

    ❏ ❏ 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. ❏ ❏...

  • Page 28: Hot Water

    AQUA PLUS — Product Manual indirect fired water heaters Troubleshooting (continued) Figure 23 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.
  • Page 29 AQUA PLUS — Product Manual 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. •...
  • Page 30 AQUA PLUS — Product Manual 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: Pipe size Flow, GPM Pipe size...
  • Page 31 AQUA PLUS — Product Manual 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. •...
  • Page 32 AQUA PLUS — Product Manual 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 AQUA PLUS — Product Manual 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 AQUA PLUS — Product Manual 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? •...
  • 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 •...
  • Page 36 AQUA PLUS — Product Manual indirect fired water heaters Troubleshooting (continued) Rapid decay of magnesium anode 1 Anodes last less than two years magnesium anode 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 AQUA PLUS — Product Manual 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 AQUA PLUS — Product Manual 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. •...

  • Page 39: Replacement Parts

    AQUA PLUS — Product Manual indirect fired water heaters Replacement parts Figure 24 Water heater replacement parts Size/Model Weil-McLain Item Description AQUA PLUS Part Number Magnesium anode replacement kit 35/45/55/85 633-500-014 (includes anode, o-ring, insulating 633-500-016 washer and brass bushing)

  • Page 40: Ahri Ratings

    AQUA PLUS — Product Manual indirect fired water heaters ® AHRI ratings AHRI certified ratings 180°F boiler water entering | 58°F to 135°F domestic water Model AQUA Minimum Minimum First Hour Continuous Heat Source First Draw Standby Heat Output Heat Source PLUS The ratings in this table are certified by Rating...

  • Page 41: Ratings With 200°F Boiler Supply Water

    AQUA PLUS — Product Manual 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: Ratings With 190°F Boiler Supply Water

    AQUA PLUS — Product Manual 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. First Hour Rating Capacity (GPH) —...

  • Page 43: Ratings With 180°F Boiler Supply Water

    AQUA PLUS — Product Manual 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. First Hour Rating Capacity (GPH) —...

  • Page 44: Dimensions

    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...

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