Weil McLain Water Heater GL E223 ADOC 0311 User Manual
TM  
®
Indirect-Fired Water Heaters  
stallation • Maintenance  
Product Manual  
artup  
• 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. BEFORE installing, read all instruc-  
tions 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 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Please read before proceeding  
Failure to adhere to the guidelines on this page can  
Hazard definitions  
result in severe personal injury,death or substantial  
property damage.  
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.  
Read all instructions before installing.Failure to follow all instruc-  
tions in proper order can cause severe personal injury, death or  
substantial property damage.  
Indicates presence of hazards that will  
cause severe personal injury, death or  
substantial property damage.  
When servicing water heater  
•
To avoid electric shock, disconnect electrical supply before  
performing maintenance.  
Indicates presence of hazards that can  
cause severe personal injury, death or  
substantial property damage.  
•
To avoid severe burns, allow water heater to cool before per-  
forming maintenance.  
Indicates presence of hazards that will  
or can cause minor personal injury or  
property damage.  
Operating restrictions  
•
Maximum domestic hot water temperature: residential sizes  
— 160°F, commercial sizes — 180°F. Pay attention to the  
water temperature warnings throughout this manual.  
Indicates special instructions on installa-  
tion, operation or maintenance that are  
important but not related to personal  
injury or property damage.  
•
•
•
Maximum boiler water temperature — 200°F.  
Maximum working pressure for tank — 150 PSIG.  
Water chemistry limits:  
This manual provides installation and  
operation guidelines for Weil-McLain  
AQUA PLUS indirect water heaters.  
The installer is responsible for ensuring  
that the installation complies with this  
manual, the boiler manual and all ap-  
plicable codes.  
•
•
•
hardness — less than 6 grains/gal.  
pH — above 6 and less than 8.  
chlorides — less than 200 ppm.  
Boiler water restrictions  
•
•
•
Thoroughly flush the boiler system (without water heater  
connected) to remove sediment.  
The water heater heat exchanger can be damaged by build-up  
or corrosion due to sediment.  
Massachusetts installations — The  
water heater must be installed by a li-  
censed plumber. The installation must  
follow all Massachusetts code require-  
ments. The domestic water piping must  
comply with the piping shown in this  
manual. See “Domestic water piping,”  
page6,fordetailsandcoderequirements.  
Boiler water (including additives) must be practically non-  
toxic, having toxicity rating or class of 1, as listed in Clinical  
Toxicology of Commercial Products.  
•
If antifreeze is used in boiler system:  
•
Local codes may require a backflow preventer on cold  
water supply line.  
Use antifreeze specifically intended for hydronic heating  
systems. Inhibited propylene glycol is recommended.  
Follow boiler manual instructions for antifreeze usage.  
Do not use automotive, ethylene glycol or petroleum-  
based antifreeze. Do not use any undiluted antifreeze.  
•
•
•
When calling or writing about the water  
heater — Please have the water heater se-  
rialnumber fromtheserial number label,  
located on the back side of the water  
heater, adjacent to the rating plate.  
Location  
•
•
This water heater is not intended for outdoor installation.  
Install the water heater so if the tank or any connections  
should leak, the water flow will not cause damage to area  
near water heater, or to lower floors of structure. When such  
locations cannot be avoided,install a suitable drain pan under  
water heater. Drain pans are available at your local plumbing  
supply store.  
Any claims for damage or shortage in  
shipment must be filed immediately  
against the transportation company by  
the consignee.  
•
This product is designed for vertical installation only.  
3
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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.  
2. AQUA PLUS water heaters are exempt from ASME  
Section VIII, Division 1 Code construction per In-  
terpretationVIII-1-86-136. Check with local codes  
for applicability.  
3. Whererecommendations inthismanualdiffer from  
local or national codes, local or national codes take  
precedence.  
Code restrictions  
National Standard Plumbing Code  
1. Single-wall heat exchanger in water heater complies  
with National Standard Plumbing Code, provided  
that:  
Recommended clearances  
Installation location must provide adequate clearances for servicing and  
proper operation of the water heater. See Figure 1.  
a. boiler water (including additives) is practically  
non-toxic, having toxicity rating or class of 1,  
as listed in Clinical Toxicology of Commercial  
Products, and  
•
1”clearance is permissible to either side of water heater,but the Instruc-  
tion label or other labels may be hidden.  
•
•
Top (vertical) clearance is 12” minimum.  
Refer to boiler manual for boiler clearances.  
b. boiler water pressure is limited to maximum 30  
PSIG by approved relief valve.  
Uniform Plumbing Code  
1. Single-wall heat exchangers are permitted if they  
satisfy all of the following requirements —  
Clearance to combustible materials  
1. Provide at least ½”clearance between all hot water pipes and combus-  
tible materials.  
a. The heat transfer medium is potable water or  
contains only substances which are recognized  
as safe by the U. S. Food and Drug Adminis-  
tration.  
Water heater placement  
b. The pressure of the heat transfer medium is  
maintained less than the normal minimum op-  
erating pressure of the potable water system.  
1. Read and comply with “Location,” page 3 of this manual.  
2. Select a convenient location for the water heater, based on domestic  
and boiler piping hook-ups.  
c. Exception: Steam complying with #a, above.  
3. Keeping the distance between boiler and water heater short will:  
d. The equipment is permanently labeled to  
indicate that only additives recognized as safe  
by the FDA shall be used in the heat transfer  
medium.  
•
•
reduce piping heat loss.  
provide minimum friction loss.  
Install levelling legs  
1. Carefully tip the water heater onto its side.  
2. Other heat exchanger designs may be permitted  
where approved by the Administrative Authority.  
2. Screw the four levelling legs into the base.  
3. Return the water heater to the upright position and set in place.  
4. Adjust the legs as necessary to level the water heater.  
4
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Pre-installation  
(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. 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. A thermal expansion tank is also  
required.  
4. If the water heater will replace a tankless coil in the boiler, discon-  
nect piping to coil or remove coil from boiler and replace with  
a cover plate. Allow water to drain from coil. Do not plug the  
tankless coil.  
Plugging tankless coil inlet and outlet will result in severe  
personal injury, death or substantial property damage.  
Studies have indicated that dangerous bacteria,  
including legionella pneumophila, can form in  
the potable water distribution system if certain  
minimum water temperatures are not maintained.  
Contact your local health department for more  
information.  
Hot Water Can Scald!  
•
•
Water heated to temperature for clothes washing,  
dish washing and other sanitizing needs can scald  
and cause permanent injury.  
Children, elderly, and infirm or physically handi-  
capped persons are more likely to be permanently  
injured by hot water.Never leave them unattended  
in bathtub or shower.Never allow small children to  
use a hot water tap or draw their own bath.  
Water heater operating restrictions  
1. Read the operating limits under “Operating restrictions,” page 3.  
Magnesium anode — The water heater is equipped with  
amagnesiumsacrificialanode.Theanodemayerodeover  
time,and should be inspected at least once annually,only  
by a qualified service technician. For installations with  
a likelihood of poor water conditions, the anode should  
be inspected at least every six months. Failure to comply  
could result in loss of protection by the anode, causing  
possible severe personal injury, death or substantial  
property damage due to water heater leakage.  
•
If anyone using hot water in the building fits  
the above description, or if state laws or local  
codes require certain water temperatures at  
hot water taps, you must take special precau-  
tions:  
•
•
Use lowest possible temperature setting.  
Install some type of tempering device,such  
as an automatic mixing valve, at hot water  
tap or waterheater.Automaticmixing valve  
must be selected and installed according  
to valve manufacturer’s recommendations  
and instructions.  
The domestic water chloride concentration must not ex-  
ceed 200 ppm. High chloride concentrations can rapidly  
disintegrate the water heater’s protective anode.  
Boiler water restrictions  
•
Water passing out of drain valves may be extremely  
hot. To avoid injury:  
1. Read the WARNINGS under “Boiler water restrictions,” page 3.  
•
•
Make sure all connections are tight.  
Direct water flow away from any person.  
Protection must be taken against excessive tem-  
perature and pressure! — Installation of a tem-  
perature & pressure (T&P) relief valve (provided  
with water heater) and a thermostatic mixing valve  
(provided by installer) is required.  
5
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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 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  
valve.  
The T&P relief valve is not intended for  
constant duty, such as relief of pressure  
due to repeated normal system expan-  
sion. Refer to expansion tank manufac-  
turer’s instructions for proper sizing.  
Failure to comply could result in severe  
personal injury, death or substantial  
property damage.  
General applications  
1. Figure2 — Thispipingconfigurationcan be used in  
most cases, except where local codes require special  
components or piping not illustrated.  
2. Some codes may require the items listed as optional,  
such as a vacuum breaker on the inlet line, or re-  
circulation piping.  
Massachusetts applications  
1. For Massachusetts code applications, or as  
required elsewhere by local codes, install the fol-  
lowing options.  
a. Thermal siphon on DHW inlet and outlet.  
b. Vacuum breaker on domestic water inlet line.  
c. Recirculation —Massachusetts codeapplica-  
tions require recirculationpiping or heat-traced  
piping if the distance from the water heater to  
the furthest fixture exceeds 100 feet. See page 8  
for details.  
Figure 3 Piping connection sizes  
Connections (inches NPT)  
Model  
DHW  
in/out  
Boiler water Recirculation  
AQUA PLUS  
in/out  
tapping  
35  
45  
¾
¾
¾
1
1
1
1
1
1
¾
¾
¾
¾
¾
55  
85  
105  
1
6
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Domestic water piping  
(continued)  
LEGEND for Figure 2, page 6  
Do not install any valve between T&P relief valve and  
tank connection, or on T&P relief valve discharge  
piping. Do not plug T&P relief valve or its discharge  
piping. Improper placement and piping of T&P re-  
lief valve can cause severe personal injury, death or  
substantial property damage.  
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.  
11 Temperature adjustment knob  
12 Anode access  
The anode is specially made for this water heater. Use  
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. 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.  
13 Mixing valve —  
— RECoMMENDED  
This symbol indicates the item is optional, unless  
required by applicable codes.  
•
See Replacement parts for thermostatic mixing valves  
available from Weil-McLain.  
1 Domestic cold water inlet connection — see Fig-  
14 Domestic cold water supply  
ure 3, page 6 for size  
When the water supply pressure is higher than  
2 Domestic hot water outlet connection — see Fig-  
70 PSIG, install a pressure-reducing valve on the  
cold water supply line to prevent leakage from the  
T & P relief valve. A thermal expansion tank is also  
required.  
ure 3, page 6 for size  
3 Domestic recirculation connection — see Fig-  
ure 3, page 6 for size  
15 Domestic mixed-temperature water supply to  
system (when used — requires mixing valve)  
4 Boiler water inlet to coil — see Figure 3, page 6 for size  
5 Boiler water outlet from coil — see Figure 3, page 6 for  
16 Domestic high-temperature hot water supply to  
size  
system  
6 Drain valve — provided by installer  
17 Heat trap loops (12” minimum) —  
18 Isolation valves  
•
Install a drain valve on the DHW inlet to the water heater  
as shown.  
7 Piping from drain valve  
Pipe from drain to floor drain, if available.  
19 Thermal expansion tank —  
•
•
REQUIRED if cold water line is equipped with a backflow  
preventer or pressure reducing valve — see ExPANSIoN  
TANk WARNING on page 6.  
8 T&P valve connection  
9 T&P relief valve — supplied with water heater  
20 Shock arrester —  
•
Use only the T&P valve supplied with the water heater.  
See Replacement parts for part number.  
Dishwashers,clotheswashers,andfast-closingpositive  
shutoff valves incorporated in the system all contrib-  
ute to creating water shock. Install a water hammer  
arrester to prevent damage to pipes and appliances.  
See control manufacturer’s instructions for applica-  
tion and installation.  
•
Install the T&P relief valve in the top center tapping, as  
shown.  
10 T&P relief valve discharge piping —  
•
must be made of material serviceable for temperatures  
of 250°F or greater.  
must be directed so that hot water flows away from all  
persons.  
must be directed to a suitable place for disposal.  
must be installed so as to allow complete draining of the  
T&P relief valve and discharge line.  
must NOT be excessively long — using more than 2 el-  
bows or 15 feet of piping can reduce discharge capacity.  
must NOT be directly connected to a drain — terminate  
discharge piping within 6” from floor — refer to local  
codes.  
21 Unions  
•
•
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.  
•
•
22 Backflow preventer —  
for Commonwealth of Massachusetts)  
—
— (required  
•
•
23 Vacuum breaker —  
24 Pressure reducing valve —  
•
•
must NOT be plugged, reduced or restricted.  
must NOT be subjected to freezing.  
•
REQUIRED when the supply pressure is higher than  
70 PSIG — A thermal expansion tank is also required.  
7
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Recirculation  
Massachusetts code applications require recircu-  
lation piping or heat-traced piping if the distance  
from the water heater to the furthest fixture exceeds  
100 feet.  
2. These branches must be balanced to prevent pipe erosion  
and unacceptable time delays at some fixtures.  
3. Balancing options include circuit setters,memory stop valves  
or factory preset devices (with flow metering provision in  
the piping).  
Maintaining domestic water  
temperature in the supply piping  
Components required  
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. ASPE recommends recirculation  
when the distance from the water heater to the furthest fix-  
ture exceeds 100 feet or the time lag for hot water to reach a  
fixture(s) exceeds 30 seconds.  
1. Forresidential applications,consult circulator manufacturer’s  
data for circulator selection and additional components  
required.  
2. On most commercial systems, install the devices shown in  
Figure 5, page 9, and any other devices or piping methods  
required by local codes.  
2. Consult local codes and American Society of Plumbing  
Engineers (ASPE) Domestic Water Heating Design Manual,  
1998, for further information.  
a. The check valves are required to prevent fixtures from  
taking hot water through the return lines.  
b. Shutoff valves are needed to allow cleaning and replacing  
balancing devices.  
Time delay at fixtures  
c. Include strainers to remove sediment which could  
damage the circulator and/or affect the flow balancing  
devices.  
1. Figure 4, page 9 is from the ASPE Domestic Water Heating  
Design Manual, 1998. It shows the time required for usable  
hot water to arrive at a fixture based on the fixture flow rate  
(available from industry and manufacturer’s data) and the  
length and diameter of the dead-end branch pipe supplying  
the fixture.  
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.  
2. The time lag should generally not exceed 30 seconds.  
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.  
3. For residential and office applications, the owner may prefer  
a limit of 10 seconds.  
4. Make provision for removal of air in all return lines. Where  
the returns cannot be vented by topmost fixtures in the  
system, install automatic air venting at the top of the return  
piping.  
4. You can use Figure 4 as a guide to determining the location  
of circulation return lines relative to fixtures.  
Balancing  
Connecting to the water heater  
1. When multiple branches are connected to the supply pip-  
ing, each branch must be connected to the recirculation  
system.  
1. Install the domestic water components as shown in Fig-  
ure 2, page 6.  
a. At each of these connections to the return piping, install  
shutoff valves, a flow metering device, check valve and a  
strainer as shown in Figure 5, page 9.  
2. See Figure 6, page 10 for the piping required to the water  
heater.  
b. Check local codes for specific installation require-  
ments.  
— Continued on page 10 —  
8
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Recirculation  
(continued)  
Figure 4 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  
0.5  
1.5  
2.5  
4.0  
10  
25  
48  
63  
91  
64  
95  
25  
10  
8
25  
21  
40  
52  
76  
53  
79  
10  
5
25  
13  
24  
31  
46  
62  
48  
10  
3
25  
8
½”  
¾”  
½”  
¾”  
½”  
¾”  
63  
119  
157  
228  
159  
238  
16  
21  
30  
21  
32  
10  
13  
18  
13  
19  
6
15  
20  
28  
20  
30  
Steel pipe  
8
11  
8
CPVC pipe  
12  
NOTE: Select branch size and length for less than 31 seconds delay.  
Figure 5 Recirculation components  
9
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
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 circula-  
tor.Aquastat is set 5° to 10° lower than mixed water  
outlet of the mixing valve (#7).  
2. The circulator cannot run continuously as bypass  
through the mixing valve will eventually allow the  
temperature on the piping to climb to the water  
heater temperature during draw periods.  
Check valves (Figure 6, items 3–6)  
1. Assure the flow of water in one direction.  
2. Each check valve functions as follows:  
a. #3 and #4 prevent bypass in the event of pres-  
sure drop.  
b. #5 prevents thermal siphoning of hot water to  
the cold water supply.  
c. #6 prevents flow of cold water to the tempered  
water supply. A draw of tempered water will  
not result in flow of cold water into the return  
loop.  
Operation  
1. During period of normal use (fixtures on) — Cir-  
culator is off. There is no flow through #6, there is  
flow through #5 equal to the flow at the fixtures,  
there is flow through #3 and/or #4 equal to flow  
at fixture.  
Potential problems  
1. Missing check valves #3 or #4 — Extreme pressure drop can cause  
reverse flow of water; hot to cold supply or cold to hot supply.  
2. When all fixtures are off — Circulator is off.There is  
no flow through #3,#4,#5 or #6.Water temperature  
in piping is cooling.  
2. Missing check valve #5 — Hot water can migrate from the water heater  
back through the cold water supply.  
3. When temperature at aquastat #2 falls 10° below  
temperature to be maintained — Circulator is on.  
There is flow through #6 equal to the minimum  
required by the mixing valve, flow through #3 and  
#4 equals the flow of the circulator. There is no  
flow through #5.  
3. Missing check valve #6 — Cold water can be forced back through the  
tempered water supply when a fixture is opened.  
4. No aquastat #2 — Circulator runs continuously. Small amount of  
water will pass through mixing valve. Eventually all hot water is flow-  
ing through valve. Recirculated water through cold port, hot water  
through hot port.  
4. Aquastat reaches temperature — Circulator is off.  
There is no flow through #3, #4, #5 or #6.  
5. Circulator too small — Mixing valve performance erratic.  
10  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side piping  
Figure 7 Zoning with circulators — direct-connected system piping  
Notes  
•
Place circulators at begin-  
nings of zones. Placing  
them at the ends of zones  
could result in heating idle  
zones.  
•
•
Size manifold piping for  
total flow of all zone cir-  
culators.  
Locate flow/check valves  
as close as possible to water  
heater boiler side connec-  
tions — to reduce heat loss  
between cycles.  
Wiring  
WMCR zone controller,  
•
optional priority — 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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
Recommended flow rate and minimum boiler-side pipe size  
Heater  
model  
Pipe  
size  
Heater  
model  
Pipe  
size  
GPM  
GPM  
GV90+ or Ultra gas boilers:  
35  
45  
55  
8
8
8
1”  
1”  
1”  
85  
14  
14  
1¼” *  
1¼” *  
2. See boiler manual for spe-  
cific details on installing  
the boiler.  
Do NoT apply the drawings in  
this manual. Refer only to the  
boiler manual.  
105  
Requires 1¼”x1” reducers at water heater  
11  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side piping  
(continued)  
Figure 8 Zoning with circulators — primary/secondary system piping  
Notes  
•
Place circulators at begin-  
nings of zones. Placing  
them at the ends of zones  
could result in heating idle  
zones.  
•
•
Size manifold piping for  
total flow of all zone cir-  
culators.  
Locate flow/check valves  
as close as possible to water  
heater boiler side connec-  
tions — to reduce heat loss  
between cycles.  
Wiring  
WMCR zone controller,  
•
optional priority — 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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
Recommended flow rate and minimum boiler-side pipe size  
Heater  
model  
Pipe  
size  
Heater  
model  
Pipe  
size  
GPM  
GPM  
GV90+ or Ultra gas boilers:  
35  
45  
55  
8
8
8
1”  
1”  
1”  
85  
14  
14  
1¼” *  
1¼” *  
2. See boiler manual for spe-  
cific details on installing  
the boiler.  
Do NoT apply the drawings in  
this manual. Refer only to the  
boiler manual.  
105  
Requires 1¼”x1” reducers at water heater  
12  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side piping  
(continued)  
Figure 9 Zoning with zone valves — direct-connected system piping  
Notes  
•
Place circulators at begin-  
nings of zones. Placing  
them at the ends of zones  
could result in heating idle  
zones.  
•
•
Size manifold piping for  
total flow of all zone cir-  
culators.  
Locate flow/check valves  
as close as possible to water  
heater boiler side connec-  
tions — to reduce heat loss  
between cycles.  
Wiring  
WMZV zone controller,  
•
optional priority — 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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
Recommended flow rate and minimum boiler-side pipe size  
Heater  
model  
Pipe  
size  
Heater  
model  
Pipe  
size  
GPM  
GPM  
GV90+ or Ultra gas boilers:  
35  
45  
55  
8
8
8
1”  
1”  
1”  
85  
14  
14  
1¼” *  
1¼” *  
2. See boiler manual for spe-  
cific details on installing  
the boiler.  
Do NoT apply the drawings in  
this manual. Refer only to the  
boiler manual.  
105  
Requires 1¼”x1” reducers at water heater  
13  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side piping  
(continued)  
Figure 10 Zoning with zone valves — primary/secondary system piping  
Notes  
•
Place circulators at begin-  
nings of zones. Placing  
them at the ends of zones  
could result in heating idle  
zones.  
•
•
Size primary piping for  
total flow of all zone cir-  
culators.  
Locate flow/check valves  
as close as possible to water  
heater boiler side connec-  
tions — to reduce heat loss  
between cycles.  
Wiring  
WMZV zone controller,  
•
optional priority — 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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
Recommended flow rate and minimum boiler-side pipe size  
Heater  
model  
Pipe  
size  
Heater  
model  
Pipe  
size  
GPM  
GPM  
GV90+ or Ultra gas boilers:  
35  
45  
55  
8
8
8
1”  
1”  
1”  
85  
14  
14  
1¼” *  
1¼” *  
2. See Boiler Manual for spe-  
cific details on installing  
the boiler.  
Do NoT apply the drawings in  
this manual. Refer only to the  
boiler manual.  
105  
Requires 1¼”x1” reducers at water heater  
14  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side piping  
(continued)  
Figure 11 Dedicated single-boiler piping  
Notes  
•
Place circulators at begin-  
nings of zones. Placing  
them at the ends of zones  
could result in heating idle  
zones.  
•
•
Size manifold piping for  
total flow of all zone cir-  
culators.  
Locate flow/check valves  
as close as possible to water  
heater boiler side connec-  
tions — to reduce heat loss  
between cycles.  
Wiring  
Connect water heater ther-  
•
mostat wires to boiler’s  
T-T terminals or heat de-  
mand connection.  
Recommended flow rate and minimum boiler-side pipe size  
Heater  
model  
Pipe  
size  
Heater  
model  
Pipe  
size  
GPM  
GPM  
GV90+ or Ultra gas boilers:  
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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
35  
45  
55  
8
8
8
1”  
1”  
1”  
85  
14  
14  
1¼” *  
1¼” *  
Do NoT apply the drawings in  
this manual. Refer only to the  
boiler manual.  
105  
Requires 1¼”x1” reducers at water heater  
2. See boiler manual for spe-  
cific details on installing  
the boiler.  
15  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side piping  
(continued)  
Figure 12 Multiple water heaters — domestic water piping  
Failure to install automatic  
mixing valve where recom-  
mended can result in severe  
personal injury or death.  
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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
2. Wire water heater thermo-  
stats in series when con-  
Figure 13 Alternate methods of revers-return piping and Easy-Fit® Manifold detail  
necting to boiler controller  
or boiler T-T terminals.  
3. Install automatic mixing  
valve at either the system  
hot water connection or  
at each water heater.  
4. See page 8 through page 10  
for additional recircula-  
tion information and pip-  
ing details.  
16  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side piping  
(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 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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
2. See boiler manual for spe-  
cific details on installing  
the boiler.  
GV90+ or Ultra gas boilers:  
Do NoT apply the drawings in this manual. Refer only to the boiler manual.  
17  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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. By designing the system properly from the start, you can  
avoid problems and have a hot water loop in a steam boiler system.  
•
The domestic water demand should preferably not exceed 1/3  
of the steam boiler capacity. Larger demand may cause difficulty  
obtaining steam as needed.  
•
•
Keepthe looptemperaturebelowthe flashpoint.Flashingcan result  
in noise and circulator damage or shortened life.  
Be sure the loop is completely closed,with no automatic or manual  
air vents, or anything that could allow air to enter the system when  
the pump shuts off.  
•
•
Pipe supply from one side of the boiler, return to the opposite  
side as shown.  
Supply from a tapping that is high enough to prevent introducing  
sediment into the piping and circulator yet still below the water  
line. Avoid the mud leg of the boiler.  
•
Use an all bronze circulator.  
•
Avoid wet rotor circulators. Select a circulator with a large  
volute, such as a typical 3-piece circulator.  
•
This will reduce clogging and will resist the corrosion potential  
from the steam condensate.  
•
•
Make sure the circulator is properly sized. If the circulator runs too  
far out on its curve, cavitation potential increases significantly.  
Use (2) flow/check valves as shown to reduce the potential for  
gravity circulation.  
Install the Honeywell L4006A aquastat in the boiler, be-  
low the water line. Set for a temperature of 180 to 190°F  
to control boiler temperature when there is no call for  
steam heating.  
•
DO NOT use spring-loaded check valves in place of the  
flow/check valves shown in Figure 16, page 19.  
Installation and start-up of water heaters  
connected to steam boilers  
Valve 7, the memory stop valve, must  
be supplied, piped and adjusted as in-  
structed. This valve allows cooler return  
water to mix with the hot water from  
the steam boiler. The valve is set to yield  
approximately 180°F water entering the  
circulator. Higher temperature water  
could cause cavitation in the circulator,  
damaging the impeller and shortening  
circulator life.  
1. See Figure 16, page 19, for suggested piping schematic.  
2. Pipe the domestic water connections to the water heater per“Do-  
mestic water piping,” page 6.  
Boiler connections for the water heater must be below  
the water line. DO NOT use the gauge glass tapping or a  
low water cut-off tapping if a LWCO is installed there.  
For steam piping, refer to the steam boiler manual.  
DO NOT install an air vent anywhere in the piping. The  
piping must be air tight.  
DO NOT connect the piping to the boil-  
er’s mud leg. This would probably cause  
excessive sediment to enter the water  
heater piping, damaging the circulator.  
3. Wire the water heater and circulator to the boiler per suggested  
wiring in Figure 15. The water heater must be wired and ready to  
operate before proceeding.Note that the L4006A aquastat is located  
in the boiler and sets a boiler operating temperature when there is  
no call for steam heating.  
The strainer in the circulator suction line  
must be serviced regularly. NOTE that  
noise from the circulator is a likely sign  
that the strainer is restricting circulator  
flow, causing cavitation.  
To fill the boiler and water heater:  
1. Follow the procedure given in Figure 16, page 19 to fill the water  
heater piping.  
2. Follow the boiler manual instructions to fill the steam boiler.  
18  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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 connec-  
tions — to reduce heat loss  
between cycles.  
Use memory stop valve 7 to  
blend some of the water re-  
turning to the boiler with the  
hot water coming from the  
boiler. This will reduce the  
possibility of flashing (cavita-  
tion) in the circulator. Slowly  
open valve 7 until temperature  
gauge 8 reads 200°F.  
Setthememorystoponvalve 7  
after adjusting. Attach a tag to  
the valve warning no to close  
or change valve position.  
NOTE — If the boiler water  
level should drop below ei-  
ther the water heater boiler  
water supply or return line,  
the filling procedure will  
have to be repeated.  
Step 5 Close valve 7. Then open valve 10.  
Filling the piping  
Step 6 Open valve 3. Water will flow through  
the circulator line, the water heater  
coil and the return piping, then out  
through valve 4 to drain. Let water run  
until all air has been removed from the  
line. Close valve 4. Then close valve 3.  
Remove hoses.  
1. Parts of the boiler water piping to the  
water heater may be higher than the wa-  
ter line, depending on the height of the  
water heater boiler supply connection.  
The piping must be air tight to prevent air  
from pocketing at the top of the piping,  
stopping flow.  
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  
responsible for inclusion  
of all required safety de-  
vices, or other miscella-  
neouspipinghardwarenot  
shown on drawing. The  
installer is responsible for  
proper sizing/selection of  
all hardware shown on this  
diagram.  
Step 7 Follow the instructions in “Water  
heater filling and start-up,” page 23,  
to fill the domestic water side of the  
water heater.  
2. The boiler MUST be filled and ready to  
operate before proceeding. Follow the  
boiler manual to fill the boiler.  
Step 8 Open valve 7 about ¼ turn for an  
3. Follow the procedure below to fill the  
boiler-to-water heater piping. See Fig-  
ure 16.  
initial setting.  
Step 9 Open isolation valves 5and 6. Make  
sure the boiler water level is correct  
per the boiler manual.  
Step 1 Close isolation valves 5 and 6 to isolate  
the boiler.  
Step 10 Start the boiler per instructions given  
in the boiler manual. Allow boiler to  
begin steaming.  
Step 2 Close valve 3 and open valve 4. Con-  
nect a cold water supply hose to  
valve 3. Connect a hose from valve 4  
to a drainable location.  
Step 11 Start the DHW circulator. Watch the  
temperature at gauge 8. Adjust valve 7  
until gauge 8 reads about 180°F with  
system at steady operation.  
Step 3 Close valve 10. Open valve 7.  
Step 4 Open valve 3. Water will flow through  
valve 7 and out through valve 4 to  
drain. Let water run until all air has  
been removed from the line. Close  
valve 4. Then close valve 3.  
2. See boiler manual for spe-  
cific details on installing  
the boiler.  
Step 12 Continue checking under varying  
DHW demand conditions to ensure  
system will operate as required.  
19  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Boiler-side wiring and controls  
Use domestic priority  
1. When possible, set controls to provide domestic  
Electrical shock hazard — Can cause severe personal  
injury,death or substantial property damage.Disconnect  
power before installing and/or servicing.  
priority — that is, on a call for domestic water  
the control switches from space heating to DHW  
only.  
2. Domestic priority ensures the fastest possible re-  
sponse to the DHW call for heat.  
Wiring requirements  
1. All wiring must be a minimum of 18 gauge and installed in accordance  
with:  
3. The smaller the water heater, the greater the need  
for rapid response.  
•
U.S.A. — National Electrical Code and any other national, state or  
local code requirements having jurisdiction.  
Canada — CSA C22.1 Canadian Electrical Code Part 1 and any  
other national, provincial and local code requirements having  
jurisdiction.  
Figure 17 Inspection hatch assembly (hatch  
cover shown transparent)  
•
2. If original wire as supplied with appliance must be replaced, Type 90°  
C or its equivalent must be used.  
3. Refer to control component instructions packed with boiler for ap-  
plication information.  
4. An optional service switch may be installed in water heater electri-  
cal circuit. This switch would only shut off the water heater, not the  
home heating system. Do not shut off water heater if there is a chance  
of freezing.  
5. All electrical contacts are shown with no power applied — off-the-  
shelf condition.  
Circulators  
1. Size priority relay for total amp draw of all circulators.  
Zone Valves  
1. Size transformer for maximum load of all zone valves.  
Wiring to the water heater  
1. Field connections to the water heater thermostat are for 24 VAC only,  
connecting to the two-pole terminal block shown in Figure 17.  
1
2
3
Temperature adjustment knob  
Inspection plate (handhole)  
Factory wires from thermostat to field wiring terminal  
block  
4
5
6
Field wiring terminal block  
M8 hex nut  
Wiring options  
1. This manual shows wiring only for use of Weil-McLain WMCR Cir-  
culator Zone Controller or Weil-McLain WMZV Zone Valve Zone  
Controller.  
Inspection plate bracket  
2. Other wiring methods may be acceptable and are left to the installer.  
20  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
•
Refer to Wiring require-  
ments on page 20.  
System piping  
•
•
Figure 7, page 11  
Figure 8, page 12  
1. This drawing is conceptual  
only. It shows representa-  
tive components and wir-  
ing.Weil-McLain does not  
represent that this drawing  
meets any particular me-  
chanical or building codes.  
The installer is respon-  
sible for inclusion of all  
required safety devices, or  
other miscellaneous pip-  
ing hardware not shown  
on drawing. The installer  
is responsible for proper  
sizing / selection of all  
hardware shown on this  
diagram.  
2. Follow component manu-  
facturer’s instructions for  
installation of all items  
shown.  
3. See boiler manual for spe-  
cific details on installing  
the boiler.  
GV90+ or Ultra gas boilers:  
Do NoT apply the drawings in this manual. Refer only to the boiler manual.  
21  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
•
Refer to Wiring require-  
ments on page 20.  
System piping  
•
•
Figure 9, page 13  
Figure 10, page 14  
Install all zone valves per valve  
manufacturer’s instructions.  
1. This drawing is conceptual  
only. It shows representa-  
tive components and wir-  
ing.Weil-McLain does not  
represent that this drawing  
meets any particular me-  
chanical or building codes.  
The installer is respon-  
sible for inclusion of all  
required safety devices, or  
other miscellaneous pip-  
ing hardware not shown  
on drawing. The installer  
is responsible for proper  
sizing / selection of all  
hardware shown on this  
diagram.  
2. Follow component manu-  
facturer’s instructions for  
installation of all items  
shown.  
3. See boiler manual for spe-  
cific details on installing  
the boiler.  
GV90+ or Ultra gas boilers:  
Do NoT apply the drawings in this manual. Refer only to the boiler manual.  
22  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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  
damage to the water heater, causing possible severe  
personal injury, death or substantial property damage.  
Verify that T&P relief valve is properly installed  
and piped as directed in this manual and per local  
code requirements.  
❏❏  
❏❏  
Boiler water restrictions  
Verify that the DHW tank and boiler-side piping  
are complete and are filled with water and pres-  
surized.  
•
•
•
Thoroughly flush the boiler system (without water heater con-  
nected) to remove sediment.  
The water heater heat exchanger can be damaged by build-up or  
corrosion due to sediment.  
Verify that all air has been bled from both domestic  
and boiler water systems.  
❏❏  
❏❏  
❏❏  
Boiler water (including additives) must be practically non-toxic,  
having toxicity rating or class of 1, as listed in Clinical Toxicology  
of Commercial Products.  
Verify that cold and hot water lines are correctly  
connected to domestic water system.  
•
If antifreeze is used in boiler system:  
•
Local codes may require a backflow preventer on cold water  
supply line.  
Use antifreeze specifically intended for hydronic heating sys-  
tems. Inhibited propylene glycol is recommended.  
Verify that supply and return piping from boiler is  
correctly connected to water heater.  
•
Check all fittings and piping for leaks.  
Verify that all wiring is installed correctly.  
❏❏  
❏❏  
❏❏  
•
•
Follow boiler manual instructions for antifreeze usage.  
Do not use automotive, ethylene glycol or petroleum-based  
antifreeze. Do not use any undiluted antifreeze.  
Set water heater thermostat according to system  
requirements. See “Water heater temperature ad-  
justment,” page 24.  
Maximum boiler-side flow rate  
•
Select the boiler-side circulator carefully.The flow rate through the  
boiler side of the water heater must not exceed the values below.  
Higher flow rates could result in an input above the rating of the  
T&P valve.  
Start boiler according to the Boiler Manual.  
❏❏  
❏❏  
•
•
Models AQUA PLUS-32, 42 and 52 — do not exceed 12 GPM.  
Models AQUA PLUS-80 and 105 — do not exceed 16 GPM.  
Verify that the boiler and water heater are operating  
correctly, per “Water heater temperature adjust-  
ment,” page 24.  
Review the following sections with the homeowner  
or system operator:  
Filling the domestic water tank  
1. Fill the domestic water tank with fresh water that meets the chemistry  
requirements above.  
❏❏  
•
•
•
Water Heater Start-Up  
2. Do not exceed a fill pressure of 70 PSIG.  
When the water supply pressure is higher than 70 PSIG, make  
sure that a pressure-reducing valve is installed on the cold  
water supply line to prevent leakage from the T&P relief valve.  
A thermal expansion tank is also required.  
Adjusting Water Heater Temperature  
Water Heater Maintenance  
3. Vent the piping as necessary to remove any trapped air.  
Start-up and operation  
1. Follow the “Start-up checklist,” page 23 to prepare for start-up.  
23  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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. The upper layer of water in  
tank can be much hotter than lower layers.  
Lowering the thermostat setting or installing automatic mixing  
valves as indicated in these instructions will reduce water tempera-  
ture levels. Consult your installer or service technician.  
At no time should boiler limit control be set above 200°F.  
This can cause severe personal injury,death or substantial  
property damage if ignored.  
Studies have indicated that dangerous bacteria, includ-  
ing legionella pneumophila, can form in the potable  
water distribution system if certain minimum water  
temperatures are not maintained. Contact your local  
health department for more information.  
Hot Water Can Scald!  
Setting the thermostat  
1. The water heater thermostat is factory set to its lowest temperature.  
This may or may not be suitable for your needs.  
•
•
Water heated to temperature for clothes washing,  
dish washing and other sanitizing needs can scald  
and cause permanent injury.  
2. Turn thermostat knob clockwise to increase water tempera-  
Children, elderly, and infirm or physically handi-  
capped persons are more likely to be permanently  
injured by hot water.Never leave them unattended  
in bathtub or shower.Never allow small children to  
use a hot water tap or draw their own bath.  
ture.  
3. Turn thermostat knob counter-clockwise to reduce water tem-  
perature.  
4. When decreasing temperature setting, the stored hot water must  
be drawn off before checking temperature at faucet.  
•
If anyone using hot water in the building fits  
the above description, or if state laws or local  
codes require certain water temperatures at  
hot water taps, you must take special precau-  
tions:  
5. Check water temperature at a hot water faucet immediately after  
first heating cycle. Further temperature adjustment may be neces-  
sary as water heating system is used. Recheck water temperature  
at faucet after adjustment.  
6. When adjusting thermostat, be sure boiler limit control is set a  
minimum 20°F higher.  
•
•
Use lowest possible temperature setting.  
Install some type of tempering device,such  
as an automatic mixing valve, at hot water  
tap or waterheater.Automaticmixing valve  
must be selected and installed according  
to valve manufacturer’s recommendations  
and instructions.  
Figure 20 Water heater temperature adjustment knob (on  
lower front of water heater)  
•
Water passing out of drain valves may be extremely  
hot. To avoid injury:  
•
•
Make sure all connections are tight.  
Direct water flow away from any person.  
Protection must be taken against excessive tem-  
perature and pressure! — Installation of a tem-  
perature & pressure (T&P) relief valve (provided  
with water heater) and a thermostatic mixing valve  
(provided by installer) is required.  
24  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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-  
tions may be extremely hot. To avoid severe personal injury,  
death or substantial property damage:  
Before operating the T&P relief  
valve,make sure no one is in front of  
or around the T&P relief valve dis-  
charge piping. Hot discharge water  
can cause severe personal injury or  
substantial property damage.  
•
•
Tighten all drain hose connections.  
Direct hot water away from all persons.  
ATTENTION USER!  
Have the water heater serviced at least once an-  
nually by a qualified service technician.  
Follow the maintenance procedures below at least  
monthly.  
Read“Water heater temperature adjustment,”page 24.  
Failure to comply with the above can result in severe  
personal injury, death or substantial property dam-  
age.  
Plugging T&P relief valve or dis-  
charge piping can cause excessive  
pressure in the water heater, result-  
ing in severe personal injury, death  
or substantial property damage.  
MONTHLY maintenance by user  
•
•
•
At least MoNTHLY, visually check valves, pipes and fittings for  
leaks.  
Check hot water supply at several outlets. Make sure water  
temperature is not too hot.  
Call qualified service technician to repair leaks or address  
problems.  
Perform the following procedures:  
Perform any procedures required by local codes.  
❏❏  
Verify system pressure both on domestic water and  
boiler water sides.  
❏❏  
MONTHLY maintenance by user  
Manually operate T&P relief valve at least once  
❏❏  
a year (see Figure 21). This will release some hot  
water. Move operating lever to open position for  
a few seconds and then move it back, allowing it  
to snap closed. After T&P relief valve is operated,  
if it continues to release water, close cold water  
inlet to water heater immediately. Follow draining  
instructions, and replace the T&P relief valve. If  
T&P relief valve weeps periodically, it may be due  
to thermal expansion. Install an expansion tank if  
not already installed.  
•
•
At least MONTHLY, visually check valves, pipes and fittings for leaks.  
Check hot water supply at several outlets.Make sure water temperature  
is not too hot.  
•
Call qualified service technician to repair leaks or address problems.  
ANNUAL start-up by qualified service  
technician  
ObtainanInspectionandservicekit(see“Replacementparts,”  
page 39) before attempting to perform the annual start-up.  
This kit contains items that will usually have to be replaced.  
Follow instructions on circulator to oil it, if oil-  
lubricated.  
❏❏  
Follow instructions in “Inspect anode and water  
heater interior,” page 26.  
❏❏  
Check water supply temperature at several outlets to ensure  
the water temperature is acceptable for intended use and  
that all temperature control devices are functioning properly.  
Read page 3 and verify that all requirements are met by the  
installation.  
Check valves, pipes and fittings for leaks.  
❏❏  
Check function of all controls and valves (see con-  
trol manufacturer’s instructions).  
❏❏  
Review homeowner’s maintenance responsibilities  
❏❏  
25  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Water heater maintenance  
(continued)  
and their frequencies, including any not listed in the following  
paragraphs.  
Figure 22 Inspection hatch assembly (hatch cover  
shown transparent)  
The purpose of the magnesium anode is to reduce  
the damaging effects of aggressive water on the wa-  
ter heater. Aggressive water will cause the anode to  
erode.  
The anode must be inspected at least annually to de-  
termine whether a new anode should be installed.  
Severe or rapid deterioration of the anode indicates  
very aggressive water. If this occurs, have the water  
tested to verify whether it is within the limits given  
under “Operating restrictions,” page 3.  
Failure to inspect the anode regularly and replace if  
necessary could result in damage to the water heater,  
causing possible severe personal injury, death or  
substantial property damage.  
1
2
3
4
5
6
Temperature adjustment knob  
Inspection plate (handhole)  
Factory wires from thermostat to field wiring terminal block  
Field wiring terminal block  
Inspect anode and water heater interior  
1. Close domestic water isolation valves.  
2. Drain the water heater completely and allow it to cool off.  
3. Remove the inspection hatch cover (Figure 24, page 39, item 8).  
M8 hex nut  
a. The temperature control bulb will have to be pulled out of the  
immersion well, located in the inspection plate.  
Inspection plate bracket  
4. After the water heater has drained and cooled, remove the inspec-  
tion plate (Figure 22, page 26, item 2).  
11. Replace the inspection plate gasket if necessary. Then  
re-install the inspection plate.Align the gasket carefully.  
DO NOT over-tighten the bolt. This could damage or  
extrude the gasket, or distort the plate.  
There will be some water remaining in the bottom of the  
water heater. This can be siphoned off or removed with  
a wet/dry vacuum.  
a. Partially unscrew the M8 hex nut (Figure 22, page 26, item 5)  
while holding the bracket (Figure 22, page 26, item 6). DO  
NOT completely remove the nut.  
12. Re-install the access cover hatch and tighten the four M8  
Phillips-head screws. Do not over-tighten the screws.  
13. Refill the water heater and restore to operation.  
14. Verify operation of boiler and water heater.  
b. Hold and turn the bracket 90 degrees,being careful not to drop  
the inspection plate inside the tank.  
c. Remove the inspection plate.  
5. Use a work light or flash light to inspect the interior of the tank.  
Drain the water heater if  
necessary during shutdown  
periods  
1. Drain the water heater if it will be shut off and exposed  
to freezing temperatures. Freezing water will expand  
and may damage water heater.  
6. Use a plastic scraper if needed to remove any accumulation on the  
coil. DO NOT use abrasives or metallic objects.  
7. Remove as much sediment as possible through the inspection  
opening.  
8. Rinse the bottom and remove remainder with a wet/dry shop  
vacuum.  
a. If boiler water contains sufficient antifreeze, then  
only the domestic water needs to be drained.  
b. If boiler water does not contain sufficient antifreeze,  
then the boiler water and the domestic water must  
be drained.  
9. Remove the magnesium anode cover and anode (Figure 24,page 39,  
items 10 and 1).  
10. Inspect the anode and replace if needed with part list in (Fig-  
ure 24, page 39). See WARNING above.  
26  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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  
jobsite 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.  
❏❏  
Stopwatch.  
❏❏  
Bucket —  
❏❏  
1 gallon or larger, with volume markings.  
Suggested parts to have on hand.  
Tank thermostat (Aquastat) — see Replacement parts for part number.  
❏❏  
Inspection and service kit — see Replacement parts for part number.  
❏❏  
Information needed before the service call  
Know the water heater model number.  
❏❏  
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 jobsite.  
❏❏  
27  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Troubleshooting  
(continued)  
Figure 23 Typical problems and causes and page location for details  
Problem  
Check possible causes  
Page  
1 Undersized water heater?  
2 Boiler system improperly sized?  
3 Check component parts.  
4 Check boiler operating tempera-  
tures.  
5 Check location of flow control  
devices.  
Insufficient  
hot water  
6 Check for air in the system.  
7 Clean the boiler water system.  
8 Check tank thermostat setting.  
29  
1 Reduce stacking  
• Lower boiler operating tempera-  
ture.  
2 Install a thermostatic mixing valve.  
3 Install a recirculation loop.  
Excessive  
domestic water  
temperature  
32  
33  
1 Undersized expansion tank?  
2 Faulty boiler expansion tank?  
3 Faulty boiler relief valve?  
4 Faulty boiler fill valve?  
Boiler relief valve  
lifting or weeping  
1 Undersized or missing domestic  
4 High domestic water supply pres-  
Temperature/  
pressure relief  
valve lifting  
water side expansion tank?  
sure?  
2 Faulty domestic water side expan-  
sion tank?  
3 Faulty T&P relief valve?  
5 Possible water hammering or pres-  
sure spikes?  
6 Check boiler operating tempera-  
ture.  
34  
35  
or weeping  
1 Check for leaks from sources other 2 T&P relief valve lifting and dis-  
Water on the  
floor near the  
tank  
than the water heater.  
charging?  
3 Loose piping connections?  
1 Check for leaks from sources other 2 Loose piping connections?  
Top of tank or  
insulation wet  
than the water heater.  
35  
37  
1 Water smells like “rotten eggs.”  
2 Milky water.  
3 Discolored water from the hot  
water faucet.  
Water quality  
problems  
28  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
•
•
For example, was the tank sized for shower heads at 2.0 gpm, while the actual heads are 5.0 gpm?  
Use a bucket and a stopwatch to determine fixture flow rates.  
•
•
Evaluate the hot water usage pattern for a day.  
Is the peak demand unusually high for the application?  
•
Has the demand for domestic hot water changed since the system was installed?  
•
A bathroom remodeling project with a newly installed whirlpool tub will substantially change the  
domestic water demand.  
2 Boiler system improperly sized?  
•
Can the boiler provide the required output to meet the domestic water load? Determine the boiler domestic  
water capacity, GPH, by the following:  
Boiler output Btuh  
Boiler DHW capacity, GPH  
=
Temp. rise °F x 8.33  
[Temp. rise °F = Required DHW temp. °F – Incoming temp. °F]  
[8.33 = Density of water (lbs/gal) x 1 Btu/lb-°F]  
•
Example — A single family home with a 3.0 GPM shower fixture and a 150,000 Btuh output boiler ca-  
pacity.  
•
•
The shower demand of 3.0 GPM equals 180 GPH (60 times the GPM).  
Is the boiler capacity enough to deliver this hot water flow at 115°F for an extended period? Determine  
the boiler capacity:  
150,000 Btuh  
Boiler DHW capacity, GPH  
=
= 277 GPH  
(115°F – 50°F) x 8.33  
•
The boiler is capable of delivering 277 GPH (or 4.6 GPM) continuously, which is enough for this  
application.  
•
•
•
Measure the BTU input to the boiler by clocking the gas meter or finding the oil flow rate based on nozzle  
size and pump pressure.  
Does the hot water system need to be wired for domestic priority? For systems in which either the storage or  
BTU’s available are marginal it is recommended to wire the domestic water heater in a priority manner.  
Is the boiler piping to the water heater properly sized to allow the required flow rate for maximum BTU  
transfer? The temperature differential of the boiler supply and return water should be 20°F to 30°F.  
29  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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  
¾”  
Flow, GPM  
1 to 4  
MBH  
Pipe size  
1½”  
Flow, GPM  
14 to 22  
MBH  
50 to 100  
100 to 180  
160 to 300  
200 to 450  
300 to 650  
1”  
4 to 8  
2”  
22 to 45  
1¼”  
8 to 14  
3 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. Check for continuity across the water heater thermostat terminals.On a call for heat,these contacts  
should closed.  
4. Continue checking for continuity while turning the thermostat knob to the lowest setting — counter  
clockwise — to satisfy the call for heat. The contacts should open, breaking the continuity.  
5. If any of these steps fail, replace the thermostat.  
•
•
Is the thermostat setting too low?  
•
If the thermostat setting is too low, the boiler may not have the opportunity to deliver the maximum  
BTU’s required to completely heat the entire volume of water stored in the tank.  
Duringa callforheatbythewaterheater,doestheboilercirculatorbeginpumping,doesthezonevalveopen,  
does the boiler fire? Check every component in the system to ensure they are properly functioning.  
30  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Troubleshooting  
(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.  
After a long standby period, the colder boiler may absorb the stored energy within the water heater  
during the initial call for heat.  
5 Check location of flow control devices.  
•
Lab tests have shown that during long standby periods the boiler piping can act as a thermal siphon and  
draw stored heat from the domestic water.  
•
Locate flow control devices (zone valve, spring check valves...) or heat trap loops in the boiler piping  
close to the water heater.  
•
Insulate all boiler piping to and from the water heater.  
6 Check for air in the system; check water heater air vent.  
•
An air-bound water heater or boiler will not circulate system water properly, resulting in a lack of heat  
transfer.  
7 Clean the boiler water system.  
•
A dirty boiler system can cause deposits to form on the water heater  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
•
This layering or stacking effect typically occurs during small draws of hot water (typically less than  
25% of the storage capacity) that are long enough to create a call for heat on the thermostat, but are  
short enough not to deplete the stored energy within the  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
Boiler side  
AQUA PLUS  
volume —  
model  
gallons  
35  
45  
1.6  
1.9  
2.2  
2.5  
3.5  
55  
85  
105  
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. This will  
simulate maximum expansion in the boiler system.  
•
If the boiler relief valve lifts and/or there is a significant increase in the boiler system pressure, the  
expansion tank is flooded or undersized.  
3 Faulty boiler relief valve?  
•
Is the boiler pressure relief valve functioning properly? Dirt and water deposits can accumulate under  
the valve seat.  
4 Faulty boiler fill valve?  
•
Is the valve filling to the correct pressure?  
33  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
•
•
Ensure the potable water expansion tank is properly sized according to the water heater volume and supply pressure.  
During long periods when there are no draws from the tank (i.e. overnight), the T&P relief valve may lift or weep due to  
thermal expansion, but may function properly during normal periods of tank draws.  
2 Faulty domestic water side expansion tank?  
•
Is the expansion tank defective, water logged or improperly charged?  
•
•
Check for failed gaskets or bladders, or a faulty Schraeder valve.  
Use a tire gauge to check the charged pressure of the tank.  
3 Faulty T&P relief valve?  
•
Is the temperature/pressure relief valve functioning properly? Dirt and water deposits can accumulate under the valve seat.  
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.  
•
This will prevent any pressure spikes or increases in pressure due to thermal expansion which may cause the T&P valve  
to lift or weep.  
5 Possible water hammering or pressure spikes?  
•
Check the domestic system for possible sources of water hammering or pressure spikes.  
•
Some appliances such as clothes washers and dishwashers utilize fast acting valves which may cause water hammering or  
pressure spikes through the domestic water system.  
•
Install water hammer arrestors as required per the manufacturer’s instructions, or install flexible connectors to isolate the  
tank from the domestic system  
6 Check boiler operating temperature.  
•
If the boiler operating temperature is too high, stacking can occur in the water heater raising the domestic water tempera-  
ture close to the boiler operating temperature. — Reduce the boiler operating temperature to 180°F. Also follow page 32  
suggestions if the problem persists.  
34  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Troubleshooting  
(continued)  
Water on the floor near the tank  
1 Check for leaks from sources other than the water heater.  
•
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?  
•
•
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.  
If the T&P relief valve is the source, refer to page 34 of this guide.  
3 Loose piping connections?  
•
•
Check all connections – boiler connections, domestic connections, etc.  
Check all the boiler connections to the water heater.  
•
A build-up of corrosion is a sure sign of a leak.  
•
Excessive force or water hammer can damage the welds where the piping connections enter the water  
heater tank.  
•
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.  
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.  
35  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Troubleshooting  
(continued)  
Rapid decay of magnesium anode  
1 Anodes last less than two years  
The purpose of the magnesium anode 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.  
Severe or rapid deterioration of the anode indicates very aggressive water. If this occurs, have the  
water tested to verify whether it is within the limits given under “Operating restrictions,” page 3.  
Failure to inspect the anode regularly and replace if necessary could result in damage to the water  
heater, causing possible severe personal injury, death or substantial property damage.  
36  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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.  
•
The bacteria survives in the water system by converting sulfate (SO4) in the water to hydrogen sulfide  
(H2S) gas.  
•
•
It is this gas that creates the “rotten egg” smell.  
The presence of hydrogen sulfide can also affect the taste of the water.  
•
•
Along with the stench caused by this bacteria, black deposits that typically indicate pipe and/or fitting  
corrosion may also appear in the water.  
In extremely high concentrations, hydrogen sulfide gas can be toxic. However, the gas is detectable  
prior to reaching harmful levels.  
The bacteria will thrive in any water system under the following conditions:  
•
•
•
•
High levels of sulfur in the water  
Activated hydrogen in the water from cathodic reactions within the tank  
Water with little or no dissolved oxygen  
Storing the domestic water below 130ºF  
•
•
Other causes of smelly water:  
•
•
•
•
•
Chlorides of magnesium and calcium gives water a bitter taste  
Chloride of sodium will produce a salty tasting water  
Sulfates above 50 ppm in the water gives the water a medicinal taste.  
Carbon dioxide in water with a low pH results in water that is fizzy.  
Iron and tannic waters will produce water with a bad taste and odor.  
Treatment  
The treatment of this situation requires the water system to be shock-chlorinated. Depending on the  
severity of the bacteria within the water system, several treatments may be needed.  
•
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, chlo-  
rine, carbon dioxide, hydrogen sulfide or others.  
As the water system pressure increases, the amount of gas that water can hold in a solution decreas-  
es.  
When air and gases are forced out of the heated water, the problem may be evident in one or both of  
the following conditions:  
•
Gases, in the form of small bubbles, may make the water appear milky from the tap, but clear after  
several minutes when those bubbles will separate.  
37  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
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. This  
can cause spurts of air or gases when opening the hot water faucet.  
•
There is generally no cure for milky water caused by dissolve gases, although it can be reduced with aer-  
ated faucets. In some applications the amount of air and gases precipitating out of the water will reduced  
in time. It should be noted that these gases are not harmful to the end user.  
3 Discolored water from the hot water faucet.  
•
The water from the hot water faucet appears discolored, either rusty, brown, black or yellow.  
•
•
Because the tank is stainless steel, which is resistant to corrosion, the problem is not tank-related.  
The problem is usually a non-toxic iron-reducing bacteria that is commonly found in soil, well water,  
water treatment plants and piping systems.  
•
•
The bacteria usually thrives in systems in which the soluble iron exceeds 0.2 ppm.  
The bacteria will feed on the soluble iron in the water, producing “rusty-color” water as a by-product  
of the feeding process.  
•
•
•
Variables in which the bacteria can thrive:  
•
•
•
Elevated levels of iron and manganese in the water  
Water with little or no dissolved oxygen  
Water storage temperatures below 140ºF  
Items that can potentially increase the presence of the bacteria:  
•
•
•
Water softeners.  
Well water.  
Long periods of no water movement.  
Treatment  
•
•
Treatment requires the water system to be shock-chlorinated.  
Depending on the severity of the bacteria within the water system, several treatments may be need-  
ed.  
•
•
•
•
Check the pH and chlorides of the water in the water heater tank and the boiler system.  
The pH must be between 6 and 8.  
Chlorides must be less than 200 ppm.  
Note the pH and chloride readings on the warranty sheet.  
•
•
Items that can affect the pH reading:  
•
•
•
•
•
Water softeners.  
Water treatment plants.  
Cl ( chlorides) added, especially during the summer  
Fl ( fluorides) added in treatment in large cities  
Elevated levels of iron, manganese, and sulfur.  
If the pH is high or low, this has a major effect on the metal tanks, piping and heat transfer surfaces.  
38  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Replacement parts  
Figure 24 Water heater replacement parts  
Size/Model  
AQUA PLUS  
Weil-McLain  
Part Number  
Item Description  
35/45/55  
85  
633500014  
633500015  
633500016  
Magnesium anode replacement kit  
(includes anode, o-ring, insulating  
washer and brass bushing)  
1
2
105  
Aqua PLUS  
Residential  
(35/45/55)  
633500020  
633500021  
Thermostat repair kit  
Aqua PLUS  
Commercial  
(85/105)  
35/45/55  
85  
633500024  
633500025  
633500026  
633500030  
633500031  
633500032  
633500036  
633500038  
633500039  
3
4
Top plastic cap replacement kit  
105  
35/45/55  
85  
Bottom plastic cap replacement kit  
(plastic cap and 4 screws)  
105  
5
6
Leveling leg replacement kit (4)  
All  
35/45/55  
85/105  
Temperature & pressure relief valve  
kit  
Inspection and service kit (includes  
inspection plate and anode seals)  
NS  
7
All  
All  
All  
633500042  
633500044  
633500046  
Inspection plate replacement kit  
Inspection hatch cover replacement  
kit  
8
¾”  
1”  
633500064  
633500037  
9
Fitting grommet  
10 Anode cover  
All  
633500048  
633500049  
633500050  
633500051  
633500052  
633500053  
633500054  
633500055  
633500056  
633500057  
633500058  
633500012  
35, Pewter  
45, Pewter  
55, Pewter  
85, Pewter  
105, Pewter  
35, Gold  
45, Gold  
55, Gold  
85, Gold  
105, Gold  
All  
NS Jacket replacement kit  
NS Mixing valve kit, 1"  
39  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
®
AHRI ratings  
AHRI certified ratings  
180°F boiler water entering | 58°F to 135°F domestic water  
Model  
AQUA  
PLUS  
Minimum  
Heat Output Heat Source  
Minimum  
First Hour  
Rating  
Continuous  
Draw Rating  
Heat Source  
Friction Loss  
First Draw  
Rating  
Standy  
Loss  
The ratings in this table are certified by  
AHRI. The conditions under which these  
ratings were obtained are listed below.  
Rate  
Flow Rate  
GPM  
Degrees F  
per hour  
GPH  
GPH  
Btu/hr  
Feet w.c.  
GPH  
These ratings were obtained with a heat  
source output rate of 134,477 Btu/hr at a heat  
source flow rate of 14 gpm. Other results will  
be obtained under different conditions.  
230.0  
203.9  
134,477  
150,488  
175,320  
178,279  
245,926  
14.0  
14.0  
13.9  
14.0  
14.0  
5.4  
26.1  
0.9  
0.8  
0.5  
0.5  
0.4  
35  
45  
These ratings were obtained with a heat  
source output rate of 150,488 Btu/hr at a heat  
source flow rate of 14 gpm. Other results will  
be obtained under different conditions.  
263.7  
322.9  
341.4  
453.7  
228.2  
265.8  
270.3  
373.0  
8.8  
4.2  
5.4  
7.1  
35.6  
57.1  
71.0  
80.8  
These ratings were obtained with a heat  
source output rate of 175,320 Btu/hr at a heat  
source flow rate of 13.9 gpm. Other results will  
be obtained under different conditions.  
55  
These ratings were obtained with a heat  
source output rate of 178,279 Btu/hr at a heat  
source flow rate of 14 gpm. Other results will  
be obtained under different conditions.  
85  
These ratings were obtained with a heat  
source output rate of 245,926 Btu/hr at a heat  
source flow rate of 14 gpm. Other results will  
be obtained under different conditions.  
105  
40  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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 Ultra Gas boiler, Ultra Oil boiler  
or GV90+ boiler applications, with supply water at 190°F, see the ratings in the boiler manual.)  
Boiler  
Heating  
Capacity  
First Hour Rating Capacity (GPH) — Boiler Water Supply at 200°F  
Do NoT exceed the boiler-side flow rate listed in “Maximum boiler-side flow rate,” page 23  
MBH  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
DHW AQUA  
temps PLUS  
35  
AQUA  
PLUS  
45  
AQUA  
PLUS  
55  
AQUA  
PLUS  
85  
AQUA  
PLUS  
105  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
50  
93  
103  
130  
157  
184  
211  
237  
243  
243  
243  
243  
243  
243  
243  
243  
243  
129  
166  
203  
241  
278  
315  
352  
363  
363  
363  
363  
363  
363  
363  
363  
124  
151  
178  
205  
232  
259  
286  
302  
302  
302  
302  
302  
302  
302  
302  
150  
188  
225  
262  
299  
337  
374  
411  
443  
443  
443  
443  
443  
443  
443  
138  
165  
192  
219  
246  
273  
300  
327  
354  
374  
374  
374  
374  
374  
374  
164  
201  
239  
276  
313  
351  
388  
425  
462  
537  
551  
551  
551  
551  
551  
148  
175  
202  
229  
256  
283  
310  
337  
363  
417  
483  
483  
483  
483  
483  
174  
211  
249  
286  
323  
360  
398  
435  
472  
547  
640  
715  
715  
715  
715  
70  
120  
147  
174  
201  
223  
223  
223  
223  
223  
223  
223  
223  
223  
223  
119  
157  
194  
231  
268  
306  
337  
337  
337  
337  
337  
337  
337  
337  
337  
90  
110  
130  
150  
170  
190  
210  
250  
300  
350  
400  
450  
500  
50  
8 GPM  
8 GPM  
8 GPM  
14 GPM  
14 GPM  
minimum  
minimum  
minimum  
minimum  
minimum  
@
@
@
@
@
1.6 ft wc  
1.6 ft wc  
1.6 ft wc  
5.4 ft wc  
7.1 ft wc  
70  
90  
110  
130  
150  
170  
190  
210  
250  
300  
350  
400  
450  
500  
8 GPM  
minimum  
8 GPM  
minimum  
8 GPM  
minimum  
14 GPM  
minimum  
14 GPM  
minimum  
@
@
@
@
@
1.6 ft wc  
1.6 ft wc  
1.6 ft wc  
5.4 ft wc  
7.1 ft wc  
41  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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 at  
least 190°F, and the boiler water flow rate must be no less than given in the tables below.  
Boiler  
Heating  
Capacity  
First Hour Rating Capacity (GPH) — Boiler Water Supply at 190°F  
Do NoT exceed the boiler-side flow rate listed in “Maximum boiler-side flow rate,” page 23  
MBH  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
DHW AQUA  
temps PLUS  
35  
AQUA  
PLUS  
45  
AQUA  
PLUS  
55  
AQUA  
PLUS  
85  
AQUA  
PLUS  
105  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
50  
93  
103  
130  
157  
184  
211  
222  
222  
222  
222  
222  
222  
222  
222  
222  
222  
129  
166  
203  
241  
278  
315  
335  
335  
335  
335  
335  
335  
335  
335  
335  
124  
151  
178  
205  
232  
259  
278  
278  
278  
278  
278  
278  
278  
278  
278  
150  
188  
225  
262  
299  
337  
374  
411  
411  
411  
411  
411  
411  
411  
411  
138  
165  
192  
219  
246  
273  
300  
327  
343  
343  
343  
343  
343  
343  
343  
164  
201  
239  
276  
313  
351  
388  
425  
462  
511  
511  
511  
511  
511  
511  
148  
175  
202  
229  
256  
283  
310  
337  
363  
417  
442  
442  
442  
442  
442  
174  
211  
249  
286  
323  
360  
398  
435  
472  
547  
640  
662  
662  
662  
662  
70  
120  
147  
174  
201  
202  
202  
202  
202  
202  
202  
202  
202  
202  
202  
119  
157  
194  
231  
268  
306  
311  
311  
311  
311  
311  
311  
311  
311  
311  
90  
110  
130  
150  
170  
190  
210  
250  
300  
350  
400  
450  
500  
50  
8 GPM  
8 GPM  
8 GPM  
14 GPM  
14 GPM  
minimum  
minimum  
minimum  
minimum  
minimum  
@
@
@
@
@
1.6 ft wc  
1.6 ft wc  
1.6 ft wc  
5.4 ft wc  
7.1 ft wc  
70  
90  
110  
130  
150  
170  
190  
210  
250  
300  
350  
400  
450  
500  
8 GPM  
minimum  
8 GPM  
minimum  
8 GPM  
minimum  
14 GPM  
minimum  
14 GPM  
minimum  
@
@
@
@
@
1.6 ft wc  
1.6 ft wc  
1.6 ft wc  
5.4 ft wc  
7.1 ft wc  
42  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS 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 at  
least 180°F, and the boiler water flow rate must be no less than given in the tables below.  
Boiler  
Heating  
Capacity  
First Hour Rating Capacity (GPH) — Boiler Water Supply at 180°F  
Do NoT exceed the boiler-side flow rate listed in “Maximum boiler-side flow rate,” page 23  
MBH  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
Boiler  
Water  
DHW AQUA  
temps PLUS  
35  
AQUA  
PLUS  
45  
AQUA  
PLUS  
55  
AQUA  
PLUS  
85  
AQUA  
PLUS  
105  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
Min GPM &  
Head Loss  
50  
93  
103  
130  
157  
184  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
200  
129  
166  
203  
240  
277  
307  
307  
307  
307  
307  
307  
307  
307  
307  
307  
124  
151  
178  
205  
232  
252  
252  
252  
252  
252  
252  
252  
252  
252  
252  
150  
187  
224  
262  
299  
336  
373  
378  
378  
378  
378  
378  
378  
378  
378  
138  
165  
192  
219  
246  
273  
300  
310  
310  
310  
310  
310  
310  
310  
310  
164  
201  
238  
275  
313  
350  
387  
424  
461  
470  
470  
470  
470  
470  
470  
148  
175  
202  
229  
256  
283  
310  
337  
363  
400  
400  
400  
400  
400  
400  
174  
211  
248  
285  
322  
360  
397  
434  
471  
545  
608  
608  
608  
608  
608  
70  
120  
147  
174  
181  
181  
181  
181  
181  
181  
181  
181  
181  
181  
181  
119  
156  
193  
231  
268  
284  
284  
284  
284  
284  
284  
284  
284  
284  
284  
90  
110  
130  
150  
170  
190  
210  
250  
300  
350  
400  
450  
500  
50  
8 GPM  
8 GPM  
8 GPM  
14 GPM  
14 GPM  
minimum  
minimum  
minimum  
minimum  
minimum  
@
@
@
@
@
1.6 ft wc  
1.6 ft wc  
1.6 ft wc  
5.4 ft wc  
7.1 ft wc  
70  
90  
110  
130  
150  
170  
190  
210  
250  
300  
350  
400  
450  
500  
8 GPM  
minimum  
8 GPM  
minimum  
8 GPM  
minimum  
14 GPM  
minimum  
14 GPM  
minimum  
@
@
@
@
@
1.6 ft wc  
1.6 ft wc  
1.6 ft wc  
5.4 ft wc  
7.1 ft wc  
43  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  
AQUA PLUS indirect-fired water heaters — Product Manual  
Dimensions  
Figure 25 Dimensions and ratings — AQUA PLUS indirect-fired water heaters  
1
2
3
4
5
Boiler water inlet (see table  
for size)  
Boiler water outlet (see  
table for size)  
Cold domestic water inlet  
(see table for size)  
Hot domestic water outlet  
(see table for size)  
Domestic water  
recirculation line (see table  
for size)  
6
7
8
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)  
9
Angle between boiler water  
connections and domestic  
water connections  
10 Connection for T&P valve  
(¾”) — valve supplied  
loose with the water  
heater; field installed  
Storage  
Connections  
Dimensions (inches)  
Ship.  
weight  
(approx.)  
DHW  
Boiler  
In/out  
water  
&
Model  
AQUA  
PLUS  
DHW  
side  
Boiler  
side  
F
G
A
B
C
D
E
In/out  
Recirc.  
Inches  
NPT  
Inches  
NPT  
Gallons  
Gallons  
Inches  
Inches  
Inches  
Inches  
Inches  
Inches  
Inches  
Pounds  
29.6  
1.6  
C\v  
C\v  
C\v  
1
1
1
1
1
1
36C\,  
7M\,  
24  
21M\,  
7C\,  
17B\,  
28  
94  
35  
45  
39.9  
53.1  
1.9  
2.2  
2.5  
3.5  
46Z\v  
60  
7M\,  
7M\,  
26  
21M\,  
21M\,  
26  
7C\,  
7C\,  
8M\,  
9M\,  
21Z\v  
28Z\,  
31Z\x  
29B\,  
37M\,  
51B\,  
50C\,  
48B\,  
111  
122  
223  
238  
29M\,  
33Z\v  
41C\,  
55  
80.6  
59Z\x  
59C\v  
10C\,  
14Z\v  
85  
109.4  
1
30  
105  
®
44  
Part number GL-E223-ADOC 0311  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Weslo Treadmill CT58 User Manual
Weslo Treadmill WCTL39102 User Manual
Westinghouse CRT Television CW50T9YW User Manual
Woodstock Router 1107907 User Manual
Wright Manufacturing Lawn Mower Sentar S User Manual
Xantech Satellite Radio 172 77 User Manual
Zanussi Cooktop 200150 User Manual
Zanussi Plumbing Product 132344 User Manual
Zanussi Range ZKG5020 User Manual
Zanussi Refrigerator 110753 User Manual