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Manual Weil-McLain GL-E223-ADOC 0311

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  • Weil-McLain GL-E223-ADOC 0311 - page 1

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

  • Weil-McLain GL-E223-ADOC 0311 - page 2

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

  • Weil-McLain GL-E223-ADOC 0311 - page 3

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

  • Weil-McLain GL-E223-ADOC 0311 - page 4

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

  • Weil-McLain GL-E223-ADOC 0311 - page 5

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

  • Weil-McLain GL-E223-ADOC 0311 - page 6

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

  • Weil-McLain GL-E223-ADOC 0311 - page 7

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

  • Weil-McLain GL-E223-ADOC 0311 - page 8

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

  • Weil-McLain GL-E223-ADOC 0311 - page 9

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Recir culation (conti nued ) Figure 4 Time lag to obtain hot water at fixture for branch lengths of 10 and 25 feet (ASPE Domestic W ater Heating Design Manual) Time in seconds required to get hot water at fixture (from ASPE) Fixture flow rate (GPM) - 0.5 1.5 2.5 4.0 Piping length (f ...

  • Weil-McLain GL-E223-ADOC 0311 - page 10

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Recir culation (conti nued ) Components Circulator (Figure 6, item 1) 1. Little flow is required to maintain a temperature in the piping. 2. Size of circulator depends on minimum flow re- quirements of the tempering valve. 3. Minimum flow r ates of the t empering valve must be maint ...

  • Weil-McLain GL-E223-ADOC 0311 - page 11

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

  • Weil-McLain GL-E223-ADOC 0311 - page 12

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

  • Weil-McLain GL-E223-ADOC 0311 - page 13

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

  • Weil-McLain GL-E223-ADOC 0311 - page 14

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

  • Weil-McLain GL-E223-ADOC 0311 - page 15

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

  • Weil-McLain GL-E223-ADOC 0311 - page 16

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

  • Weil-McLain GL-E223-ADOC 0311 - page 17

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

  • Weil-McLain GL-E223-ADOC 0311 - page 18

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

  • Weil-McLain GL-E223-ADOC 0311 - page 19

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

  • Weil-McLain GL-E223-ADOC 0311 - page 20

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

  • Weil-McLain GL-E223-ADOC 0311 - page 21

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

  • Weil-McLain GL-E223-ADOC 0311 - page 22

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

  • Weil-McLain GL-E223-ADOC 0311 - page 23

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

  • Weil-McLain GL-E223-ADOC 0311 - page 24

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

  • Weil-McLain GL-E223-ADOC 0311 - page 25

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

  • Weil-McLain GL-E223-ADOC 0311 - page 26

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

  • Weil-McLain GL-E223-ADOC 0311 - page 27

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

  • Weil-McLain GL-E223-ADOC 0311 - page 28

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

  • Weil-McLain GL-E223-ADOC 0311 - page 29

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

  • Weil-McLain GL-E223-ADOC 0311 - page 30

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

  • Weil-McLain GL-E223-ADOC 0311 - page 31

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

  • Weil-McLain GL-E223-ADOC 0311 - page 32

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

  • Weil-McLain GL-E223-ADOC 0311 - page 33

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

  • Weil-McLain GL-E223-ADOC 0311 - page 34

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

  • Weil-McLain GL-E223-ADOC 0311 - page 35

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

  • Weil-McLain GL-E223-ADOC 0311 - page 36

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

  • Weil-McLain GL-E223-ADOC 0311 - page 37

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

  • Weil-McLain GL-E223-ADOC 0311 - page 38

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual • This is similar to the reaction that occurs as air bubbles form on the walls of a pan shortly befor e the water begins to boil. • The release of dissolved gas can also create air pockets and air locks in the water system piping. This can cause spurts of air or gases when opening ...

  • Weil-McLain GL-E223-ADOC 0311 - page 39

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

  • Weil-McLain GL-E223-ADOC 0311 - page 40

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

  • Weil-McLain GL-E223-ADOC 0311 - page 41

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

  • Weil-McLain GL-E223-ADOC 0311 - page 42

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Ratings with 190°F boiler supply water For water heater to achieve the rated performance below: Boiler water must be supplied to the water heater at at least 190°F , and the boile r water flow rate m ust be no less than given in the tables below . Boiler Heating Capacity MBH First H ...

  • Weil-McLain GL-E223-ADOC 0311 - page 43

    AQUA PLUS indirect - fired w a ter hea ters — Pr oduct Manual Ratings with 180°F boiler supply water For water heater to achieve the rated performance below: Boiler water must be supplied to the water heater at at least 180°F , and the boile r water flow rate m ust be no less than given in the tables below . Boiler Heating Capacity MBH First H ...

  • Weil-McLain GL-E223-ADOC 0311 - page 44

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

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