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Weil-McLain GL-E223-ADOC 0311 manual

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Table of contents for the manual

  • Page 1

    Part number GL-E223-ADOC 0311 This manual must only be used b y a qualified heating installer/serv ice tec hnician. BEFORE installing , read all instruc- tions in this manual and all other information shipped with the water heat er . P erform st eps in the order giv en. Failur e to co mply could result in sev ere personal injury , death or substan[...]

  • Page 2

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Contents Please read before pr oceeding 3 W hen serv icing water heater . . . . . . . . . . . . . . . . . . . . 3 Operating restric tions . . . . . . . . . . . . . . . . . . . . . . . . 3 Boiler water r estric tions . . . . . . . . . . . . . . . . . . . . . . . 3 Location . . . . . . .[...]

  • Page 3

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Please r ead befor e pr oceeding Failur e to adher e to the guidelines on this page can res ult in sever e personal injur y , death or substantia l property damage. R ead all inst ructio ns befor e insta lling. Fail ure to follo w all instru c- tions in proper order can cause severe pe[...]

  • Page 4

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Pr e-installation Figure 1 Clearance recommendations Codes 1. Installation must co nform w ith instructions in this manual and, where applicable: • local, stat e, pro vincial, and national codes, la ws, regulations and ordinanc es. • in C ana da — B1 49 .1 o r B1 49 .2 In st al l[...]

  • Page 5

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Pr e-installation (conti nued ) Hot W ater Can Scald! • W ater heated to te mperature for clothes washing, dish washing and other sanitizing needs can scald and cause permanent injur y . • Children, elderly , and infirm or physically handi- capped persons are mor e likely to be pe[...]

  • Page 6

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Domestic water piping Figure 2 DHW piping Piping overview THERMAL EXP ANSION T ANK — If a backflow prev enter , check valv e, or pres- sur e re duci ng val ve is piped on cold wate r inlet of water heater , you must install an expansion tank on c old water suppl y line to p re ven t[...]

  • Page 7

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Domestic water piping (conti nued ) LEGEND for Figure 2, page 6 Domestic water supplied to fixtures that could pose an injur y hazard due to high temperature, such as sh ow er s a n d f a u ce t s, s h o ul d b e e qu i pp e d w i t h a temperature regulating device, such as an anti-s[...]

  • Page 8

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Recir culation Mas sac hus ett s cod e app lica tio ns re qui re reci rc u- lation piping or heat-traced piping if the distance fr om the wat er heat er to the furth est fixtur e ex cee ds 100 feet. Maintaining domestic water temperature in the supply piping 1. Recirculation is used t[...]

  • Page 9

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Recir culation (conti nued ) Figure 4 Time lag to obtain hot water at fixture for branch lengths of 10 and 25 feet (ASPE Domestic W ater 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 (f[...]

  • Page 10

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Recir culation (conti nued ) 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 re- quirements of the tempering valve. 3. Minimum flow r ates of the t empering valve must be maint[...]

  • Page 11

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Figure 7 Zoning with circulators — dir ect-connected system piping Notes • Place circulat ors at beg in- n i ng s o f z o n es . P l a c i n g them at the ends of zones coul d result in heating idle zones. • Siz e ma ni fo ld pip in g f or total flow of all zone cir- culators. ?[...]

  • Page 12

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Boiler-side piping (conti nued ) Figure 8 Zoning with circulators — primary/secondary system piping Notes • Place circulato rs at beg in- n i ng s o f z o n es . P l a c i n g them at the ends of zones coul d result in heating idle zones. • Siz e ma ni fo ld pip in g f or total ?[...]

  • Page 13

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Boiler-side piping (conti nued ) Figure 9 Zoning with zone valves — direct-connected system piping Notes • Place circulat ors at beg in- n i ng s o f z o n es . P l a c i n g them at the ends of zones coul d result in heating idle zones. • Siz e ma ni fo ld pip in g f or total ?[...]

  • Page 14

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Boiler-side piping (conti nued ) Figure 10 Zoning with zone valves — primary/secondar y system piping Notes • Place circulato rs at beg in- n i ng s o f z o n es . P l a c i n g them at the ends of zones coul d result in heating idle zones. • S i z e p r im a r y p i p i n g f o [...]

  • Page 15

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Boiler-side piping (conti nued ) Figure 11 Dedicated single-boiler piping Notes • Place circulat ors at beg in- n i ng s o f z o n es . P l a c i n g them at the ends of zones coul d result in heating idle zones. • Siz e ma ni fo ld pip in g f or total flow of all zone cir- culato[...]

  • Page 16

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Boiler-side piping (conti nued ) Figure 12 Multiple water heaters — domestic water piping Figure 13 Alternate methods of revers-return piping and Easy-Fit® Manifold detail Fa i l u re to in s t a l l a u t o m a t i c m i x i n g v a l ve w he re re c o m - men de d ca n res ul t in[...]

  • Page 17

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Boiler-side piping (conti nued ) Figure 14 Multiple water heaters and dedicated multiple boilers — boiler water piping Notes • See lege nd a nd detail s i n Figure 12, page 16. 1. This drawin g is co nce ptua l only . It shows rep resenta- t i ve p i p i n g co m p on e n t s and l[...]

  • Page 18

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Connecting to a low-pr essur e steam boiler Special considerations W hen designi ng steam and dome stic hot wate r systems , there are some key issues that m ust be take n int o c onsideration d uring the initial de- sign phase. By designing the system properly from the star t, you can[...]

  • Page 19

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Connecting to a low-pr essur e steam boiler (cont inued ) Figure 16 Low pressur e steam boiler application — Domestic water heating using water pumped from steam boiler Notes • Loca te flo w / check valv e as close as possible to water heater boiler side connec- tion s — to red [...]

  • Page 20

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Boiler-side wiring and contr ols Electrical shock hazard — Can cause severe personal inj ury , death or sub sta ntia l pr ope rty damag e. Dis co nnec t power befo re installing and / or serv icing. Wiring requir ements 1. All wiring must be a minimum of 18 gauge and installed in acc[...]

  • Page 21

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Wiring — zoning with cir culators Notes • Also refer to th e WMC R manual and W e il-McLain Boiler Zone W iring Guide for further details. • Refe r to Wir in g re qu ir e- ments on page 20. System piping • Figure 7, page 11 • Figure 8, page 12 1. This drawin g is co nce ptua [...]

  • Page 22

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Wiring — zoning with zone valves Notes • Also ref er to the W MZV manual and W e il-McLain Boiler Zone W iring Guide for further details. • Refe r to Wir in g re qu ir e- ments on page 20. System piping • Figure 9, page 13 • Figure 10, page 14 Install all zo ne val ves per va[...]

  • Page 23

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual W ater heater filling and star t-up The i nst al lat ion a nd wa ter che mist r y m ust m eet the requir ements below . Failure t o comply could result in damage to the water heater , causing possible severe personal injury , death or substantial pr opert y damage. Boiler water restri[...]

  • Page 24

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Hot W ater Can Scald! • W ater heated to te mperature for clothes washing, dish washing and other sanitizing needs can scald and cause permanent injur y . • Children, elderly , and infirm or physically handi- capped persons are mor e likely to be permanently injur ed by hot water [...]

  • Page 25

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual W ater heater maintenance Boiler water — r ead and comply with all r equire ments under “Boiler water r estric tions, ” page 3. W ater from opened drain valves, unions and other connec- tions ma y be extr emely hot. T o a void severe personal injury , death or substantial pro per[...]

  • Page 26

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual W ater heater maintenance (conti nued ) and their frequencies, including any not listed in the following paragr aphs. Figure 22 Inspection hatch assembly (hatch cover shown transparent) 1 T emperature adjustment knob 2 Inspection plate (handhole) 3 Factory wires from thermostat to fie[...]

  • Page 27

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting Preparation for tr oubleshooting T ools needed  Electr ical meter to measur e voltage and c ontinuity .  Press ure gauge (such as W atts #276H300 test gauge).  T emper ature gauge.  Stopwat ch.  Bucket — 1 gallon or larger , with volume markings. Sugg[...]

  • Page 28

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) Insufficient hot water 1 Und ersized water heate r? 2 Boiler system improperly siz ed? 3 Check component parts. 4 Check boiler operating tempera- tures. 5 Check location of flow contr ol devices. 6 Check for air in the system. 7 Clean the boiler water [...]

  • Page 29

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) 1 Undersized water heater? • There are many methods of sizing various applicatio ns, i.e. ASHRAE sizing tables or ASPE domestic water heating design manual. • Confirm the water demand r equired for the application. • Confirm the flow rates of th[...]

  • Page 30

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) • Is the cir culator between the boiler and the water heater properly sized to p rovide enough flow for maxi- mum BTU transfer? Check the table belo w : Pipe size Flow , GPM MBH Pipe size Flow , GPM MBH ¾” 1 to 4 50 to 100 1 ½” 14 to 22 200 to 4[...]

  • Page 31

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) 4 Check boiler operating temperatures. • If possible, increase the boiler o perating temperature to 180°F or 200°F . • Maintain a minimal t emperature in the boiler during non-heating seasons. • A boiler ty pically has a higher standby loss than [...]

  • Page 32

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) Excessive domestic water temperatur e 1 Reduce stacking. • Ex cessiv e water temperature is us ually the result of sta cking within the water heater . • Stacking is the occurrence of various water temperatures lay ering within the water heater with t[...]

  • Page 33

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) Boiler r elief valve lifting or weeping 1 Undersized expansion tank? • Insufficient allo wance for expansion on the boiler sid e can cause the boiler pressur e relief valv e to lift. • The additional quantity of boiler water contained in the outer t[...]

  • Page 34

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) T emperature/pr essur e relief valve lifting or weeping 1 Undersized or missing domestic water side expansion tank? • Is ther e a thermal expansion tank installed on the domestic supply piping and is it pr operly sized? • A ther mal expansion tank is[...]

  • Page 35

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) W ater on the floor near the tank 1 Check for leaks from sour ces other than the water heater . • Check for possible water seepag e through foundation cracks. Did the wat er appear after a heavy rain? 2 Is the source of water fr om the T&P r elief[...]

  • Page 36

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual T r oubleshooting (conti nued ) Rapid decay of magnesium anode 1 Anodes last less than two years The purpose of the magnesium anode is to reduc e the damaging effects of agg ressiv e water on the water heater . A ggressiv e water will cause the anode to erode. The anode must be inspect[...]

  • Page 37

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual W ater quality problems 1 W ater smells like “r otten eggs.” • The most common cause of water to smell like “rotten eggs ” is a non-toxic sulfat e reducing bacteria. • The bacteria usually enters into the water system through a break in the supply piping or during construct[...]

  • Page 38

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual • This is similar to the reaction that occurs as air bubbles form on the walls of a pan shortly befor e 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 [...]

  • Page 39

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Item Description Size/Model A QU A PLUS W eil-McLain Part Number 1 Magnesium anode replacement kit (includes anode, o-ring, insulating washer and brass bushing) 35/45/55 633500014 85 633500015 105 633500016 2 Thermostat repair kit Aqua PLUS Residential (35/45/55) 633500020 Aqua PLUS Co[...]

  • Page 40

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual AHRI ratings Model A QU A PLUS AHRI certified ratings 180°F boiler water entering | 58°F to 135°F domestic water First Hour Rating Continuous Draw Rating Minimum Heat Output Rate Minimum Heat Source Flow Rate Heat Source Friction Loss First Draw Rating Standy Loss The ratings in th[...]

  • Page 41

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Ratings with 200°F boiler supply water For water heater to achieve the rated performance below : Boiler water must be supplied t o the water heater at 200°F , and the boiler water flow rate must be no less than giv en in the tables below . (For Ul tra Gas boiler , Ultra Oil boiler o[...]

  • Page 42

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct 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 at least 190°F , and the boile r water flow rate m ust be no less than given in the tables below . Boiler Heating Capacity MBH First H[...]

  • Page 43

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct 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 at least 180°F , and the boile r water flow rate m ust be no less than given in the tables below . Boiler Heating Capacity MBH First H[...]

  • Page 44

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Dimensions Figure 25 Dimensions and ratings — AQUA PLUS indirect-fir ed water heaters Model A QU A PLUS Storage Connections Dimensions (inches) Ship. weight (approx.) DHW side Boiler side DHW In/Out & Recirc. Boiler water In/Out ABCDE F G Gallons Gallons Inches NPT Inches NPT In[...]