Indirect Water Heaters INSTALLATION START-UP MAINTENANCE PARTS Models WI030 / WI040 / WI050 WI060 / WI080 / WI100 For Residential and Commercial Use This manual must only be used by a qualified installer/service technician. Read all instructions in this manual before installing. Perform steps in the given order. Failure to comply could result in substantial property damage, severe personal injury, or death.
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important product information. DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
B. BOILER CONNECTIONS ........................................................................................................................................................... 9 C. DOMESTIC PIPING INLET ......................................................................................................................................................... 9 D. AUXILIARY CONNECTIONS ............................................................................................................................
NOTE: Install all system components and piping in such a manner that does not reduce the performance of any fire rated assembly. DO NOT USE THIS WATER HEATER IF ANY PART HAS BEEN UNDERWATER. Immediately call a qualified service technician. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. B. WHEN SERVICING THE WATER HEATING SYSTEM To avoid electric shock, disconnect electrical supply before performing maintenance.
PRODUCTS TO AVOID Spray cans containing fluorocarbons Permanent wave solutions Chlorinated waxes/cleaners Chlorine-based swimming pool chemicals Calcium chloride used for thawing Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric or Muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine-type bleaches, laundry detergents, and cleaning solvents Adhesives used to fasten building products Table 1 – Chemical Contaminants AREAS
Figure 1 – Specifications and Dimensions A. LOCATING THE WATER HEATER This water heater is certified for indoor use only. DO NOT INSTALL OUTDOORS. Outdoor installations ARE NOT covered by warranty. WHL-007 Rev. 10.3.
Choose a location for the water heater as centralized to the piping system as possible. Also, locate the water heater and domestic water piping where it will not be exposed to freezing temperatures. All piping should be insulated. Additionally, place the water heater so that the drain, controls, and inlets/outlets are easily accessible.
o Operating temperatures above 135 F will further accelerate the build-up of lime scale and may shorten the service life of the water heater. Failure of the water heater due to lime scale build-up on the heating surface, low pH, or other chemical imbalance IS NOT covered by the warranty. Outlined on the following page are water quality parameters which need to be met in order for the system to operate efficiently for many years.
When filling the water heater, open a hot water tap to release air in the tank and piping. Failure to do so could lead to improper water heater operation. DO NOT pipe this water heater with black iron, galvanized steel, steel, or lead pipe. Doing so will result in premature product failure and property damage, and WILL VOID the product warranty. B. BOILER CONNECTIONS Use two wrenches when tightening water piping at heater. Use one wrench to prevent the heater return or supply line from turning.
Use both thread tape and pipe dope to install an NPT brass T&P relief valve for hot water storage tanks, as required by local codes, but not less than valves certified as meeting the requirements for relief valves for hot water heaters (ANSI Z21.22 and CAN1-4.4) by a nationally recognized lab that maintains periodic inspection of production listed equipment. Make sure the relief valve is sized to the BTU/Hour capacity and storage capacity of the water heater.
This water heater can deliver scalding water. Be careful whenever using hot water to avoid scalding injury. Certain appliances, such as dishwashers and automatic clothes washers may require increased water temperature. By setting the thermostat on this heater to obtain the increased water temperature required by these appliances, you may create the potential for scald injury.
J. PIPING Figure 4 – Typical Expansion Tank Application with Auxiliary Line – LP-451-A NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet. 3. All circulators should have an integral flow check. 4.
Figure 5 – Zoning with Zone Valves – LP-451-B NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet. 3. All circulators should have an integral flow check. 4. Drains and check valve between unit and storage tank will assist in purging air from system. 5.
Figure 6 – Zoning with Circulators NOTES: 1. Minimum pipe size should match connection size. Upsize pipe accordingly if greater flow is required. 2. A thermal expansion tank suitable for potable water must be sized and installed within this piping system between the backflow preventer and the cold water inlet. 3. All circulators should have an integral flow check. 4. Drains and check valve between unit and storage tank will assist in purging air from system. 5.
B. WIRING Wiring is to be done in accordance with all applicable local and state codes. Turn off all power related to the boiler starting and wiring procedures. It is recommended that a disconnect switch be installed between the boiler control and water heater. When wiring the water heater and controls, be sure to label all wires for ease of future maintenance. Wiring errors can cause improper and dangerous operation.
Figure 9 – Wiring with Zone Valves PART 5 – START-UP AND OPERATION 1. Fill the water heater by opening the cold water shut-off valve. Purge air from the system by opening a hot water outlet at a fixture in a kitchen or bathroom. When water flows freely from the outlet, the system is purged. 2. Check the system for leaks. Fix any leaks before continuing the installation. Any leaks can result in serious property damage and personal injury. 3.
If draining of the heater is necessary, open the temperature and pressure valve or a hot water tap to prevent vacuum buildup in the tank and piping. Risk of scald injury increases as you increase water temperature.
PART 6 – MAINTENANCE AND TROUBLESHOOTING Periodic maintenance should be performed by a qualified service technician to assure that all the equipment is operating safely and efficiently. The owner should make necessary arrangements with a qualified heating contractor for periodic maintenance of the heater. Installer must also inform the owner that the lack of proper care and maintenance of the heater may result in a hazardous condition.
TROUBLESHOOTING NO HOT WATER PROBLEM Zone valve not opening Circulator not operating Tank control set too low Boiler control set too low Wiring incorrect Tank control failure Zone valve failure Circulator failure Air trap in loop POSSIBLE SOLUTION Open manually to replace.
CUSTOMER INSTALLATION RECORD FORM The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.
