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Weil-McLain Aqua Logic Product Manual Download Page 29

A

QUA

 L

OGIC

  

COMPANION

 

WATER

 

HEATER

 — 

Product Manual

Troubleshooting

Preparation for troubleshooting

Documents needed

 

❏

WM97+ Boiler manual

 

❏

Mixing valve instruction manual

 

❏

Aqua Logic (CWH) Product manual

 

❏

Get the latest boiler manual and Aqua Logic (CWH) manual revisions from www.Weil-McLain.com.

 

❏

Review all manuals before leaving for the job site.

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 temperature sensors — see Replacement parts for part number.

Information needed before the service call

 

❏

Boiler model number.

 

❏

CP number.

 

❏

Have the boiler manual and wiring and piping schematics readily available.

Troubleshooting procedures

 

&OLLOWTHETROUBLESHOOTINGGUIDELINESSTEPBYSTEP

. Always double-check your results. 

Skipping or not completing steps can lead to wrong conclusions, repeated callbacks to the 

job site and unhappy customers.

Part number 635-500-156/1113

29

Summary of Contents for Aqua Logic

Page 1: ... shipped with the boiler before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage s NSTALLATION s 3TARTUP s AINTENANCE s 0ARTS Product Manual Part number 635 500 156 1113 High Performance Companion Water Heater Boiler sold separately WM97 FOR 7 AS IRED 7ATER OILERS ...

Page 2: ... Logic CWH circulator mounting 13 Boiler water connections 13 Boiler CWH piping 70 or 110 Left side mixing valve 14 CONNECTIONS TO BOILER AND SYSTEM 14 Aqua Logic CWH circulator mounting 15 Boiler water connections 15 Boiler CWH piping 155 Right side mixing valve 16 CONNECTIONS TO BOILER AND SYSTEM 16 Aqua Logic CWH circulator mounting 17 Boiler water connections 17 Boiler CWH piping 155 Left side...

Page 3: ...onsists of the following s Position the Aqua Logic CWH under the boiler and check fit of the piping access cover Orient with DHW connections on either side by rotating the water heater 180 s Mount the Aqua Logic CWH circulator street tee bushing and drain valve s Connect the flexible lines from the circulator and Aqua Logic CWH boiler connections to the boiler domestic water connections on the botto...

Page 4: ...tifreeze Location s This water heater is not intended for outdoor installation s 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 s This p...

Page 5: ...ad Content b California Health and Safety Code 116875 known as AB 1953 2006 c Louisiana House Bill HB 471 Louisiana s Lead reduction Law d Vermont Act No 193 2008 Consumer Products Prohibition against Lead e Maryland House Bill 372 Statute 12 605 Business Occupa tions and Professionals Plumbers Lead Free Materials Code restrictions ATIONAL 3TANDARD 0LUMBING ODE 1 Single wall heat exchanger in wate...

Page 6: ...ents 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 7HEN THE SUPPLY PRESSURE IS HIGHER THAN 03 install a pres sure reducing valve on cold water supply line to prevent water loss through T P relief valve A thermal e...

Page 7: ...st provide all of the functionality of the AMX302TLF 3 The mixing valve kit includes the mixing valve upper fitting cold water tee and flex connector line OLLOW THE INSTRUCTIONS IN THE MIXING VALVE MANUFAC TURER S MANUAL SUPPLIED WITH THE MIXING VALVE KIT Be sure to set the mixed water temperature as directed and to instruct the homeowner See warnings and danger information on page 6 Failure to inst...

Page 8: ...al injury death or substantial property damage ENERAL APPLICATIONS 1 See Figure 6 This domestic water piping configuration can be used in most cases except where local codes require special components or piping not illustrated 2 See next page for legend 3 Some codes may require the items listed as optional such as a vacuum breaker on the inlet line or recirculation piping 4 Recirculation when requi...

Page 9: ...ems 5 5a and 6 according to the instructions supplied with the mixing valve 6f AH DO NOT USE The water from this port is not regulated by the mixing valve 7 T P relief valve mounted in top of CWH supplied with Aqua Logic CWH s Use only the T P valve supplied with the water heater See Replacement parts for part number s Install the T P relief valve as shown in the piping con nection instructions in...

Page 10: ...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 2 The time lag should generally not exceed 30 seconds 3 For residential and office applications the owner may prefer a limit of 10 seconds 4 You can use Figure 7 as a guide to determining the location of circ...

Page 11: ...e on left side of CWH page 14 b WM97 155 boiler Mixing valve on right side of CWH page 16 Mixing valve on left side of CWH page 18 Components see Figure 9 2ECIRCULATION PUMP 1 Little flow is required to maintain a temperature in the piping 2 Size of pump depends on minimum flow require ments of the mixing valve 3 Minimum flow rates of the mixing valve must be maintained minimumforHoneywellAMX302TLF i...

Page 12: ...nnections Make sure a gasket is placed in each the hex fittings on the hose ends No pipe dope or tape is needed DO NOT over tighten gasket would be damaged 3ERVICE TEE v SHIPPED LOOSE WITH QUA OGIC 7 Install the service tee in the location shown in this manual to provide location for the boiler drain valve item 16 A bushing 1 x NPT is supplied for mounting the boiler drain valve as shown in this ma...

Page 13: ...Logic CWH circulator mounting s 4HE CIRCULATOR 534 BE MOUNTED IN THE POSITION SHOWN PUMPING OUT OF THE WATER HEATER TOWARD THE BOILER 7 RETURN This is required to flow boiler water through the water heater in the correct direction s Rotate the lower circulator flange adapt er 10 clockwise looking down on the flange This is necessary to ensure the circulator electrical housing will clear the inside of...

Page 14: ...h for boiler water Aqua Logic CWH supply and return connections Make sure a gasket is placed in each the hex fittings on the hose ends No pipe dope or tape is needed DO NOT over tighten gasket would be damaged 3ERVICE TEE v SHIPPED LOOSE WITH QUA OGIC 7 Install the service tee in the location shown in this manual to provide location for the boiler drain valve item 16 A bushing 1 x NPT is supplied f...

Page 15: ... Logic CWH circulator mounting s 4HE CIRCULATOR 534 BE MOUNTED IN THE POSITION SHOWN PUMPING OUT OF THE BOILER TOWARD THE QUA OGIC 7 This is required to flow boiler water through the water heater in the correct direction s Rotate the lower circulator flange adapt er 10 counterclockwise looking down on the flange This is necessary to ensure the circulator electrical housing will clear the inside of th...

Page 16: ...d loose for field installation Use one hose each for boiler water Aqua Logic CWH supply and return connections Make sure a gasket is placed in each the hex fittings on the hose ends No pipe dope or tape is needed DO NOT over tighten gasket would be damaged 3ERVICE TEE v SHIPPED LOOSE WITH QUA OGIC 7 Install the service tee in the location shown in this manual to provide location for the boiler drain...

Page 17: ...CWH circulator mounting s 4HE CIRCULATOR 534 BE MOUNTED IN THE POSITION SHOWN PUMPING OUT OF THE WATER HEATER TOWARD THE BOILER 7 RETURN This is required to flow boiler water through the water heater in the correct direction s Rotate the lower circulator flange adapt er 10 clockwise looking down on the flange This is necessary to ensure the circulator electrical housing will clear the inside of the p...

Page 18: ... sure a gasket is placed in each the hex fittings on the hose ends No pipe dope or tape is needed DO NOT over tighten gasket would be damaged 3ERVICE TEE v SHIPPED LOOSE WITH QUA OGIC 7 Install the service tee in the location shown in this manual to provide location for the boiler drain valve item 16 A bushing 1 x NPT is supplied for mounting the boiler drain valve as shown in this manual USHING FO...

Page 19: ...IDES OF THE QUA OGIC 7 PIPING ACCESS COVER The example shown here is just one pos sibility Aqua Logic CWH circulator mounting s 4HE CIRCULATOR 534 BE MOUNTED IN THE POSITION SHOWN PUMPING OUT OF THE BOILER TOWARD THE QUA OGIC 7 This is required to flow boiler water through the water heater in the correct direction Boiler water connections s 4HE QUA OGIC 7 BOILER WATER SUPPLY AND RETURN LINES 534 BE...

Page 20: ...ler and to the connector at the Aqua Logic CWH circulator c The Aqua Logic CWH tank sensor harness is factory wired to the sensors in the CWH tank Route the harness end through the right side opening and attach to the sensor harness connector in the boiler 5 ROMMETS The harnesses are fitted with grommets to seal the bot tom openings Press the grommets through the openings and work into position The...

Page 21: ...s 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 5 Vent the piping as necessary to remove any trapped air Start up checklist Verify that T P relief valve is properly installed and piped as directed in this manual and per local code requirements Verify that...

Page 22: ...ltiple fixtures will be running NORMAL A balance of performance and efficiency Delivers hot water for a shower sinks or faucets continually except WM97 70 model General setting for most times of the day ECONOMY Saves energy by operating with lower boiler temperatures and storing tank at lower temperature for lowest standby losses Not recommended for showering with 70 F temperature rise Ideal setting...

Page 23: ...LIEF VALVE AT LEAST ONCE A YEAR see Fig ure 18 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 wa ter close cold water inlet to water heater immediately Follow draining instructions and replace the T P relief valve If T P relief valve weeps periodi...

Page 24: ...oduct Manual WM97 Control settings Advanced IGURE WM97 control menu access accessing contractor menus press and hold the UP and DOWN buttons for 7 seconds to go from any screen to the CONTRACTOR MENU screen Part number 635 500 156 1113 24 ...

Page 25: ...heating while Aqua Logic CWH call for heat is present This could present a freeze hazard for some installa tions if theAqua Logic CWH temperature sensors were reading incorrectly and created a constant call to the control ADJUST SCHEDULES WEEKDAYS WEEKENDS 1 Use this setting to setup a schedule during the weekdays and weekends to have the DHW performance modes change at certain times throughout th...

Page 26: ...LOGIC COMPANION WATER HEATER Product Manual WM97 Control settings Advanced continued IGURE Contractor 7 3 44 3 menus see Figure 21 page 27 for setting values and descriptions Part number 635 500 156 1113 26 ...

Page 27: ...tlet temperature the control should use for the performance mode OILER IFF N 2 F 2 F 2 F 10 F Boiler restarts burner if there is a demand and boiler temperature has dropped below Boiler Target minus Boiler Diff On OILER IFF FF 10 F 10 F 10 F 10 F Control shuts down the burner if boiler supply water temperature exceeds Boiler Target plus Boiler Diff Off INIMUM 7 LOWER 3PEED minimum RPM the blower c...

Page 28: ...OGIC COMPANION WATER HEATER Product Manual IGURE Contractor 6 7 3 44 3 menus see Figure 21 page 27 for setting values and descriptions WM97 Control settings Advanced continued Part number 635 500 156 1113 28 ...

Page 29: ...ge such as Watts 276H300 test gauge Temperature gauge Stopwatch Bucket 1 gallon or larger with volume markings Suggested parts to have on hand Tank temperature sensors see Replacement parts for part number Information needed before the service call Boiler model number CP number Have the boiler manual and wiring and piping schematics readily available Troubleshooting procedures OLLOW THE TROUBLESHO...

Page 30: ...y boiler fill valve Tank heat exchanger coil leaking 34 Temperature pressure relief valve lifting or weeping Undersized or missing domestic water side expansion tank Faulty domestic water side expansion tank Faulty T P relief valve High domestic water supply pres sure Possible water hammering or pressure spikes Boiler operating temperature too high 35 Water on the floor near the tank Check for leaks...

Page 31: ...Compare to the capacities listed at the end of this manual to ensure the WM97 boiler and Aqua Logic CWH water heater are correctly sized 3 Check component parts s Is the WM97 control set properly and operating correctly s Review WM97 Boiler manual and this manual to check control settings s If water heater control is set to SCHEDULE check whether the problem is occurring during times when the oper...

Page 32: ...se s Remove drainage hose and return by pass valve to the normal position 6 Clean the boiler water system s A dirty boiler system can cause deposits to form on the water heater coil This insulates the coil reducing the heat transfer s Clean the boiler system per the boiler manufacturer s instructions s Install a strainer in the boiler piping on older installations or for systems likely to carry se...

Page 33: ...sistance at known temperatures ice point room temperature and sea level boiling point For ice point and boiling point insert the sen sor in water at that temperature Use an ohmmeter to read resistance value To check whether the WM97 control is correctly sensing temperature you can use a resistance decade box Connect the decade box tem porarily in place of a sensor and read the correspond ing tempe...

Page 34: ...ure This will simulate maximum expansion in the boiler system s 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 s Is the boiler pressure relief valve functioning properly Dirt and water deposits can accumulate under the valve seat 4 Faulty boiler fill valve s Is the valve fill...

Page 35: ...re relief valve functioning properly Dirt and water deposits can accumulate under the valve seat 4 High domestic water supply pressure s Check the domestic supply pressure entering the water heater s 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 s This will prevent any pressure spikes or increases in...

Page 36: ...ck all the boiler connections to the water heater Check drain valve for leakage s A build up of corrosion is a sure sign of a leak s Excessive force or water hammer can damage the welds where the piping connections enter the water heater tank Remove the front of the Aqua Logic CWH enclosure to check tank and connections s If water is leaking from around one of the tank connections a weld may have ...

Page 37: ...elow 130ºF s Other causes of smelly water s Chlorides of magnesium and calcium gives water a bitter taste s Chloride of sodium will produce a salty tasting water s Sulfates above 50 ppm in the water gives the water a medicinal taste s Carbon dioxide in water with a low pH results in water that is fizzy s Iron and tannic waters will produce water with a bad taste and odor s Treatment s The treatment...

Page 38: ...ble iron exceeds 0 2 ppm s The bacteria will feed on the soluble iron in the water producing rusty color water as a by product of the feeding process s Variables in which the bacteria can thrive s Elevated levels of iron and manganese in the water s Water with little or no dissolved oxygen s Water storage temperatures below 140ºF s Items that can potentially increase the presence of the bacteria s...

Page 39: ...19 220 Wire harness top and lower temperature sensors not shown 591 391 998 230 Wire harness circulator not shown 591 391 999 240 Circulator Taco 3 speed with integral flow check valve DO NOT SUBSTITUTE another circulator model 511 405 145 250 Circulator flange with 90 degree elbow 560 907 735 260 Circulator flange 1 NPT 563 910 026 270 Circulator flange bolts 562 136 260 280 Circulator flange nuts 561...

Page 40: ...se TR The required temperature rise is the differ ence between TO and TI Use the closest value in the Ratings table next page Example a home in Philadelphia requires 115 F domestic water What is the required temperature rise 1 The groundwater temperature for the Philadelphia area is 47 F 4 2 The required domestic water outlet temperature is 115 F 4 3 The required temperature rise is the difference...

Page 41: ... 1 7 2 3 1 6 Speed 1 Lo 7 4 1 3 4 2 7 3 2 2 6 2 5 2 4 1 6 Speed 1 Lo 7 4 2 3 5 3 1 3 2 2 7 2 5 2 5 1 6 Speed 3 Hi OILER ODEL QUA OGIC 7 APACITY 0 50 F 4EMP 2ISE For DHW entering temperature of 65 F capacities will decrease at higher DHW inlet water temperatures QUA OGIC 7 0ERFORMANCE ODE 0UMP 3PEED IGH 170 F Storage ORMAL 150 F Storage CONOMY 135 F Storage GPM 8 min Draw GPM 15 min Draw GPM Contin...

Page 42: ...First Draw Rating Gallons Gallons Degrees F per hour GPH GPH Btu hr GPM Feet w c GPH QUA OGIC 7 18 2 1 4 2 5 172 187 113 000 14 0 3 6 15 The ratings in this table are certified by AHRI The conditions under which these ratings were obtained are listed below These ratings were obtained with a heat source output rate of at least 113 000 Btu hr at a heat source flow rate of 14 gpm Other results will be ...

Page 43: ...t Enclosure front and rear sections snap together Front portion can be pulled forward to expose the interior for service and inspection QUA OGIC 7 PIPING ACCESS COVER OILER WATER 2 452 CONNECTION TO BOILER v 04 OILER WATER 3500 9 CONNECTION FROM BOILER v 04 4OP TANK TEMPERATURE SENSOR 4 0 RELIEF VALVE TAPPING Ðv 04 OWER TANK TEMPERATURE SENSOR 7 INLET CONNECTION Ðv 04 7 OUTLET CONNECTION Ðv 04 IXI...

Page 44: ...44 AQUA LOGIC COMPANION WATER HEATER Product Manual ...

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