® FOR 7- 'AS &IRED 7ATER "OILERS Product Manual s )NSTALLATION s -AINTENANCE s 3TARTUP s 0ARTS WM97+ High Performance Companion Water Heater (Boiler sold separately) This manual must only be used by a qualified heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.
AQUA LOGIC — Product Manual COMPANION WATER HEATER Contents 0AGE WM97+ Boiler with Aqua Logic Heater (CWH) 3 WM97+ Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Aqua Logic (CWH) . . . . . . . . . . . . . . . . . . . . . . . . . 3 Please read before proceeding When servicing water heater Operating restrictions . . . . Boiler water restrictions . . . Location . . . . . . . . . . . . . . . . . . .
AQUA LOGIC COMPANION WATER HEATER — Product Manual WM97+ Boiler with Aqua Logic (CWH) Aqua Logic is the brand name for the Companion Water Heater for the WM97+ boiler. In the instruction manuals and boiler controls the abbreviation CWH may be used and is synonymous for Aqua Logic and the Companion Water Heater. WM97+ Boiler Installation summary Follow the boiler manual, this manual, and all applicable codes. Installation consists of the following: WM97+ s Mount boiler on the wall.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Please read before proceeding (AZARD DElNITIONS 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.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Pre-installation 4HE INCH MIXING VALVE SIDE CLEARANCE BELOW IS -!.$!4/29. The 1½” clearance on the opposite side is strongly recommended (a smaller clearance will make servicing more difficult). ADDITIONAL clearance may be needed if piping is routed on both sides of the boiler/water heater. Codes 1.
AQUA LOGIC COMPANION WATER HEATER Pre-installation — Product Manual (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.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Aqua Logic (CWH) Mixing valve The mixing valve assembly shown below and in the piping diagrams throughout this manual are for the Honeywell AMX302TLF. $!.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Domestic water piping Piping overview 4(%2-!, %80!.3)/. 4!.+ — 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.
AQUA LOGIC COMPANION WATER HEATER Domestic water piping — Product Manual (continued) LEGEND for Figure 6, page 8 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 LOGIC COMPANION WATER HEATER Recirculation — Product Manual (if used) -ASSACHUSETTS 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 LOGIC COMPANION WATER HEATER Recirculation — Product Manual (if used) (continued) 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. 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.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — 70 or 110 / Right-side mixing valve CONNECTIONS TO BOILER AND SYSTEM 4HE !QUA ,OGIC #7( CAN BE PLACED WITH ITS $(7 CONNECTIONS ON THE LEFT SIDE OR ON THE RIGHT SIDE BY ROTATING THE UNIT DEGREES 4HIS INSTRUCTION IS FOR INSTALLATIONS WITH THE #(7 WITH ITS $(7 CONNECTIONS ON THE 2)'(4 SIDE 4HE BOILER SHOWN MUST BE EITHER A MODEL 7- OR 7- "OILER WATER 2%452.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — — Product Manual 70 or 110 / Right-side mixing valve (cont.) &IGURE Typical piping for WM97+70 or 110 — CWH installed with rightside mixing valve All piping must comply with the instructions in the WM97+ Boiler manual. 0IPING CAN BE ROUTED OUT EI THER SIDE OR BOTH SIDES OF THE !QUA ,OGIC #7( PIPING ACCESS COVER The example shown here is just one possibility.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — 70 or 110 / Left-side mixing valve CONNECTIONS TO BOILER AND SYSTEM 4HE !QUA ,OGIC #7( CAN BE PLACED WITH ITS $(7 CONNECTIONS ON THE LEFT SIDE OR ON THE RIGHT SIDE BY ROTATING THE UNIT DEGREES 4HIS INSTRUCTION IS FOR INSTALLATIONS WITH THE #(7 WITH ITS $(7 CONNECTIONS ON THE ,%&4 SIDE 4HE BOILER SHOWN MUST BE EITHER A MODEL 7- OR 7- "OILER WATER 2%452.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — — Product Manual 70 or 110 / Left-side mixing valve (cont.) &IGURE Typical piping for WM97+70 or 110 — CWH installed with leftside mixing valve All piping must comply with the instructions in the WM97+ Boiler manual. 0IPING CAN BE ROUTED OUT EI THER SIDE OR BOTH SIDES OF THE !QUA ,OGIC #7( PIPING ACCESS COVER The example shown here is just one possibility.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — 155 / Right-side mixing valve CONNECTIONS TO BOILER AND SYSTEM 4HE !QUA ,OGIC #7( CAN BE PLACED WITH ITS $(7 CONNECTIONS ON THE LEFT SIDE OR ON THE RIGHT SIDE BY ROTATING THE UNIT DEGREES 4HIS INSTRUCTION IS FOR INSTALLATIONS WITH THE #(7 WITH ITS $(7 CONNECTIONS ON THE 2)'(4 SIDE 4HE BOILER SHOWN MUST BE A MODEL 7- "OILER WATER 2%452.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — — Product Manual 155 / Right-side mixing valve (cont.) &IGURE Typical piping for WM97+155 — CWH installed with right-side mixing valve All piping must comply with the instructions in the WM97+ Boiler manual. 0IPING CAN BE ROUTED OUT EI THER SIDE OR BOTH SIDES OF THE !QUA ,OGIC #7( PIPING ACCESS COVER The example shown here is just one possibility.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — 155 / Left-side mixing valve CONNECTIONS TO BOILER AND SYSTEM 4HE !QUA ,OGIC #7( CAN BE PLACED WITH ITS $(7 CONNECTIONS ON THE LEFT SIDE OR ON THE RIGHT SIDE BY ROTATING THE UNIT DEGREES 4HIS INSTRUCTION IS FOR INSTALLATIONS WITH THE #(7 WITH ITS $(7 CONNECTIONS ON THE ,%&4 SIDE 4HE BOILER SHOWN MUST BE A MODEL 7- "OILER WATER 2%452.
AQUA LOGIC COMPANION WATER HEATER Boiler/CWH piping — — Product Manual 155 / Left-side mixing valve (cont.) &IGURE Typical piping for WM97+155 — CWH installed with left-side mixing valve All piping must comply with the instructions in the WM97+ Boiler manual. 0IPING CAN BE ROUTED OUT EI THER SIDE OR BOTH SIDES OF THE !QUA ,OGIC #7( PIPING ACCESS COVER The example shown here is just one possibility.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Wiring %LECTRICAL SHOCK HAZARD — Can cause severe personal injury, death or substantial property damage. Disconnect power before installing and / or servicing. !QUA ,OGIC #7( CIRCULATOR — The Aqua Logic (CWH) circulator is shipped loose with the CWH and must be installed as instructed in this manual. Connect circulator and sensor harnesses 1.
AQUA LOGIC COMPANION WATER HEATER — 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 Start-up checklist ❏ Verify that T&P relief valve is properly installed and piped as directed in this manual and per local code requirements.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Aqua Logic (CWH) Performance Mode quick set-up 3EE PAGE FOR PERFORMANCE RATINGS AT ()'( 0%2&/2-!.#% ./2-!, AND %#/.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Water heater maintenance Boiler water — read and comply with all requirements under “Boiler water restrictions,” page 4. Water from opened drain valves, unions and other connections may be extremely hot.
AQUA LOGIC COMPANION WATER HEATER — Product Manual WM97+ Control settings — Advanced &IGURE WM97+ control menu access — accessing contractor menus — press and hold the UP and DOWN buttons for 7 seconds to go from any screen to the CONTRACTOR MENU screen 24 Part number 635-500-156/1113
AQUA LOGIC COMPANION WATER HEATER — Product Manual WM97+ Control settings — Advanced This could present a freeze hazard for some installations if the Aqua Logic (CWH) temperature sensors were reading incorrectly and created a constant call to the control. DHW SETTINGS 1. If a Aqua Logic (CWH) is used, the settings for control operation during Aqua Logic (CWH) calls for heat are set under the DHW SETTINGS menus. 2. The settings apply ONLY to Zone 1. DHW PERFORMANCE: 1.
AQUA LOGIC COMPANION WATER HEATER — Product Manual WM97+ Control settings — Advanced (continued) &IGURE Contractor $(7 3%44).
AQUA LOGIC COMPANION WATER HEATER — Product Manual WM97+ Control settings — Advanced (continued) &IGURE $EFAULT $(7 0ERFORMANCE -ODE 3ETTINGS menus (see Figure 19, page 24 for access information) Parameters 4ANK 3TORAGE 4ARGET — Upper Sensor Set Point 4ANK $IFF /N HIGH NORMAL ECONOMY VACATION DISABLED/ OFF 170°F 150°F 135°F 50°F 2°F 2°F 2°F 0°F None Description of Parameter Target temperature to modulate boiler output to.
AQUA LOGIC COMPANION WATER HEATER — Product Manual WM97+ Control settings — Advanced (continued) &IGURE Contractor !$6!.#%$ $(7 3%44).
AQUA LOGIC COMPANION WATER HEATER — Product Manual Troubleshooting Troubleshooting procedures &OLLOW 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.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) &IGURE Typical problems and causes and page location for details Problem Check possible causes Insufficient hot water Excessive domestic water temperature Boiler relief valve lifting or weeping Temperature/ pressure relief valve lifting or weeping Undersized water heater? High-flow shower heads? Boiler system improperly sized? Check component parts. Check boiler operating temperatures.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Insufficient hot water 1 Undersized water heater? s There are many methods of sizing various applications, i.e. ASHRAE sizing tables or ASPE domestic water heating design manual. s Confirm the water demand required for the application. s Confirm the flow rates of the fixtures. s For example, was the tank sized for shower heads at 2.0 gpm, while the actual heads are 5.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Insufficient hot water (continued) 5 Check for air in the system s An air-bound water heater or boiler will not circulate system water properly, resulting in a lack of heat transfer. s Air can be trapped in piping loop sections, the tank coil or the flexible water lines between the boiler and Aqua Logic (CWH). s Connect a drainage hose to the boiler supply piping purge valve (shown in WM97+ manual suggested piping).
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Excessive domestic water temperature 1 Adjust WM97+ control settings and check operation. s Follow instructions in the boiler manual and this manual to adjust tank temperature and boiler water temperature. s If controls are set properly, check tank sensor installation and operation. s See the illustration at right for locations of the sensor wells. The lower well is on the side opposite the DHW connections.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Boiler relief valve lifting or weeping 1 Undersized expansion tank? s Insufficient allowance for expansion on the boiler side can cause the boiler pressure relief valve to lift. s The tank must be sized to handle the total volume of water in the boiler system, the boiler and all interconnecting piping. The volume for the Aqua Logic (CWH) boiler piping and heat exchanger is 1.4 gallons.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Temperature/pressure relief valve lifting or weeping 1 Undersized or missing domestic water side expansion tank? s Is there a thermal expansion tank installed on the domestic supply piping and is it properly sized? s A thermal expansion tank is required if the domestic supply piping includes a backflow preventer or pressure reducing valve.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Water on the floor near the tank 1 Check for leaks from sources other than the water heater. s 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? s 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.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Water quality problems 1 Water smells like “rotten eggs.” s The most common cause of water to smell like “rotten eggs” is a non-toxic sulfate reducing bacteria. s The bacteria usually enters into the water system through a break in the supply piping or during construction/maintenance of the supply piping. s The bacteria survives in the water system by converting sulfate (SO4) in the water to hydrogen sulfide (H2S) gas.
AQUA LOGIC COMPANION WATER HEATER Troubleshooting — Product Manual (continued) Water quality problems (continued) s s s 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.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Replacement parts )TEM &IGURE Water heater replacement parts 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 $ESCRIPTION Tank Jacket front Jacket back Jacket bottom Jacket top Jacket pipe access cover Jacket retainer magnets (4 required) Leveling legs (3 required) Riveted nuts Grommet, 1.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Determine required temperature rise Determine domestic water inlet water temperature — TI Determine required domestic water outlet temperature — TO Determine required domestic water temperature rise — TR T1 is the groundwater temperature typical for the boiler location. This is the required temperature exiting the mixing valve. The required temperature rise is the difference between TO and TI. Use the closest value in the Ratings table, next page.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Ratings !QUA ,OGIC #7( #APACITY '0- 70°F 4EMP 2ISE (For DHW entering temperature of 45°F — capacities will decrease at higher DHW inlet water temperatures) !QUA ,OGIC #7( 0ERFORMANCE -ODE "OILER -ODEL (IGH .
AQUA LOGIC COMPANION WATER HEATER — Product Manual ® AHRI ratings !(2) CERTIlED RATINGS & BOILER WATER ENTERING \ & TO & DOMESTIC WATER 7ATER (EATER -ODEL !QUA ,OGIC #7( Potable Water Volume Heat Source Water Volume Standby Heat Loss Continuous Draw Rating First Hour Rating Minimum Heat Output Rate from Heat Source Minimum Heat Source Flow Rate Heat Source Friction Loss First Draw Rating Gallons Gallons Degrees F per hour GPH GPH Btu/hr GPM Feet w.c. GPH 18.2 1.4 2.
AQUA LOGIC COMPANION WATER HEATER — Product Manual Dimensions &IGURE Dimensions — Aqua Logic Companion Water Heater, right-side mixing valve orientation — All dimensions in INCHES !QUA ,OGIC #7( WATER HEATER TANK AND ENCLOSURE Tank can be oriented with DHW inlet/ outlet connections on right or rotated 180° to place DHW connections on the left. Enclosure front and rear sections snap together. Front portion can be pulled forward to expose the interior for service and inspection.
AQUA LOGIC 44 COMPANION WATER HEATER — Product Manual
