® ® Series 2 Indirect-Fired Water Heaters Product Manual • Installation • Maintenance • Startup • Parts ® User — Read important user safety information found on page 3, page 27 and page 28. Installation and service should only be performed by a qualified service technician. Retain this manual for future reference. This manual must only be used by a qualified heating installer/service technician.
® 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
® 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.
® AQUA PLUS Series 2 indirect-fired water heaters — Product Manual Pre-installation Codes Figure 1 Clearance recommendations 1. Installation must conform with instructions in this manual and, where applicable: • local, state, provincial, and national codes, laws, regulations and ordinances. • in Canada — B149.1 or B149.2 Installation Code - latest edition. 2. AQUA PLUS® water heaters are exempt from ASME Section VIII, Division 1 Code construction per Interpretation VIII-1-86-136.
® AQUA PLUS Series 2 indirect-fired water heaters Pre-installation (continued) — Product Manual Domestic water piping requirements 1. Install unions on all piping for easy removal of water heater. 2. Use dielectric unions or couplings to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe. 3.
® AQUA PLUS Series 2 indirect-fired water heaters — Product Manual Domestic water piping Piping overview Figure 2 DHW piping THERMAL EXPANSION TANK — If a backflow preventer, check valve, or pressure reducing valve is piped on cold water inlet of water heater, you must install an expansion tank on cold water supply line to prevent normal thermal expansion from repeatedly forcing open T&P relief valve.
® AQUA PLUS Series 2 indirect-fired water heaters 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.
® AQUA PLUS Series 2 indirect-fired water heaters — Product Manual Recirculation Massachusetts code applications require recirculation piping or heat-traced piping if the distance from the water heater to the furthest fixture exceeds 100 feet. Maintaining domestic water temperature in the supply piping 1. Recirculation is used to reduce wait time for water use, to minimize hot water and energy waste caused during the waiting period, and to prevent degradation of the system supply water temperature.
® AQUA PLUS Series 2 Recirculation Figure 5 indirect-fired water heaters — Product Manual (continued) Time lag to obtain hot water at fixture for branch lengths of 10 and 25 feet (ASPE Domestic Water Heating Design Manual) Time in seconds required to get hot water at fixture (from ASPE) Fixture flow rate (GPM) - 0.5 Piping length (feet) Copper pipe Steel pipe CPVC pipe 1.5 2.5 4.
® AQUA PLUS Series 2 Recirculation indirect-fired water heaters — Product Manual (continued) Components Figure 6 Recirculation piping Circulator (Figure 6, item 1) 1. Little flow is required to maintain a temperature in the piping. 2. Size of circulator depends on minimum flow requirements of the tempering valve. 3. Minimum flow rates of the tempering valve must be maintained. Aquastat (Figure 6, item 2) 1. Used to control the on-off position of the circulator.
® 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.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side piping Figure 8 — Product Manual (continued) Zoning with circulators — primary/secondary system piping Notes • • • Place circulators at beginnings of zones. Placing them at the ends of zones could result in heating idle zones. Size manifold piping for total flow of all zone circulators. Locate flow / check valves as close as possible to water heater boiler side connections — to reduce heat loss between cycles.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side piping Figure 9 — Product Manual (continued) Zoning with zone valves — direct-connected system piping Notes • • • Place circulators at beginnings of zones. Placing them at the ends of zones could result in heating idle zones. Size manifold piping for total flow of all zone circulators. Locate flow / check valves as close as possible to water heater boiler side connections — to reduce heat loss between cycles.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side piping — Product Manual (continued) Figure 10 Zoning with zone valves — primary/secondary system piping Notes • • • Place circulators at beginnings of zones. Placing them at the ends of zones could result in heating idle zones. Size primary piping for total flow of all zone circulators. Locate flow / check valves as close as possible to water heater boiler side connections — to reduce heat loss between cycles.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side piping — Product Manual (continued) Figure 11 Dedicated single-boiler piping Notes • • • Place circulators at beginnings of zones. Placing them at the ends of zones could result in heating idle zones. Size manifold piping for total flow of all zone circulators. Locate flow / check valves as close as possible to water heater boiler side connections — to reduce heat loss between cycles.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side piping — Product Manual (continued) Figure 12 Multiple water heaters — domestic water piping Failure to install automatic mixing valve where recommended can result in severe personal injury or death. 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side piping — Product Manual (continued) Figure 14 Multiple water heaters and dedicated multiple boilers — boiler water piping Notes • See legend and details in Figure 12, page 16. 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes.
® 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.
® 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.
® AQUA PLUS Series 2 indirect-fired water heaters — Product Manual Boiler-side wiring and controls Electrical shock hazard — Can cause severe Figure 17 Wiring the control “General Connection” 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.
® AQUA PLUS Series 2 indirect-fired water heaters 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. — Product Manual (continued) Figure 20 Wiring the control to the ECO (1176-120/121) boiler controls will connect to the AcuTemp 2000WM thermostat.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side wiring and controls Figure 22 Wiring the control to the GV90+ (1135-700) boiler controls will connect to the AcuTemp 2000WM thermostat. (continued) Figure 24 Wiring the control to the Ultra (1176-100) boiler controls will connect to the AcuTemp 2000WM WH 7 6 5 4 3 2 1 thermostat. P16 Call for heat demand 2 (Default for thermostat) 60 70 60 70 Call for heat demand 3.
® AQUA PLUS Series 2 indirect-fired water heaters Boiler-side wiring and controls — Product Manual (continued) 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.
® AQUA PLUS Series 2 indirect-fired water heaters — Product Manual Mounting and wiring the Control - New Installations 1. Locate the sensor leads on the top of the tank. 4. Insert the sensor wire into the channel in the back of the control. 2. Route the sensor wire through the opening in the rear of the control. 5. Attach the control to the top plastic cap of the tank and secure with two (2) screws. 3. Plug the AquaPlus sensor wire into the sensor input. The terminals are not polarity sensitive. 6.
® 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.
® 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.
® 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.
® 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.
® AQUA PLUS Series 2 indirect-fired water heaters — Product Manual Troubleshooting Troubleshooting procedures Follow the troubleshooting guidelines step by step. Always double-check your results. Skipping or not completing steps can lead to wrong conclusions, repeated callbacks to the job site and unhappy customers. Preparation for troubleshooting Tools needed ❏❏ Electrical meter to measure voltage and continuity. ❏❏ Pressure gauge (such as Watts #276H300 test gauge). ❏❏ Temperature gauge.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (continued) Figure 29 Typical problems and causes and page location for details Problem Insufficient hot water Check possible causes 1 2 3 4 Undersized water heater? Boiler system improperly sized? Check component parts. Check boiler operating temperatures. Page 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.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (continued) Insufficient hot water 7 Undersized water heater? • There are many methods of sizing various applications, i.e. ASHRAE sizing tables or ASPE domestic water heating design manual. • Confirm the water demand required for the application. • Confirm the flow rates of the fixtures. • For example, was the tank sized for shower heads at 2.0 gpm, while the actual heads are 5.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (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.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (continued) Excessive domestic water temperature 1 Reduce stacking. • Excessive water temperature is usually the result of stacking within the water heater. • Stacking is the occurrence of various water temperatures layering within the water heater with the hottest water in the uppermost layer.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (continued) Boiler relief valve lifting or weeping 2 Faulty boiler expansion tank? • Is the expansion tank defective, waterlogged or improperly charged? • Check for failed gaskets or bladders, or a faulty Schraeder valve. • Use a tire gauge to check the charge pressure of the tank. • Turn the boiler limit up to a higher setting and let the system run at a higher temperature.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (continued) Temperature/pressure relief valve lifting or weeping 4 High domestic water supply pressure? • Check the domestic supply pressure entering the water heater. • If the pressure is over 70 psi it is recommended to install a pressure reducing valve. A thermal expansion tank is required if a PRV is installed.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (continued) Top of tank or insulation wet 1 Check for leaks from sources other than the water heater • Check for possible overhead pipes leaking onto the tank. 2 Loose piping connections? • Check all connections – piping connections to the tank and elsewhere if the vicinity. • Check around valve stems. • A build-up of corrosion around a joint is a sure sign of a leak.
® AQUA PLUS Series 2 indirect-fired water heaters Troubleshooting — Product Manual (continued) Water quality problems (continued) 2 Milky water. • When water is initially drawn from the faucet it appears to be milky or cloudy, but it becomes clear after the water is allow to stand for several minutes. • This is usually an indication that the water contains high levels of soluble gases, such as oxygen, chlorine, carbon dioxide, hydrogen sulfide or others.
® AQUA PLUS Series 2 indirect-fired water heaters — Product Manual Replacement parts Figure 30 Indirect Water Heater replacement parts Item Description 1 2 3 Thermostat repair kit (Control and sensor included) Top plastic cap replacement kit Bottom plastic cap replacement kit (plastic cap and 4 screws) Size/Model AQUA PLUS® Part Number ® AQUA PLUS Residential 35/45/55/85/105 633-600-012 35/45/55 633-500-024 85 633-500-025 105 633-500-026 35/45/55 633-500-030 85 633-500-031 105 633
® 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 Potable Water Volume Heat Source Water Volume First Draw Rating Standby Heat Loss Continuous Draw Rating First Hour Rating Minimum Heat Output Rate Minimum Heat Source Flow Rate Heat Source Friction Loss (Gal) (Gal) (Gal/hr) Degrees F per hour (Gal/hr) (Gal/hr) (MBH) GPM
® 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.
® 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.
® 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.
® 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 dime
® AQUA PLUS Series 2 44 indirect-fired water heaters — Product Manual Part number 633-600-020/0118
