Table of Contents
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Manual
Plus 100/110/119
This manual must only be used by a qualified heating installer/service technician.
including this manual and any related manuals or supplements. Perform steps in the order given. Failure to comply
could result in severe personal injury, death or substantial property damage.
User —
Read important user safety information found on pages 2, 18, 19 and 20. Installation and service should only
be performed by a qualified service technician. Retain this manual for future reference.
PLUS Line
Indirect-Fired Water Heaters
Series 3
• Installation
• Startup
GOlD P
30/40/60/80
lus
• Maintenance
• Parts
P
40/60/80
lus
Before installing
, read all instructions,
Part Number PLUS-E017-A/1206
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Table of Contents
Related Manuals for Weil-McLain PLUS LINE PLUS-E017-A/1206
Summary of Contents for Weil-McLain PLUS LINE PLUS-E017-A/1206
- Page 1 Manual Plus 100/110/119 This manual must only be used by a qualified heating installer/service technician. including this manual and any related manuals or supplements. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. User — Read important user safety information found on pages 2, 18, 19 and 20. Installation and service should only be performed by a qualified service technician. Retain this manual for future reference. PLUS Line Indirect-Fired Water Heaters Series 3 • Installation • Startup GOlD P 30/40/60/80 • Maintenance • Parts 40/60/80 Before installing , read all instructions, Part Number PLUS-E017-A/1206...
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Page 2: Hot Water Can Scald
PLUS LINE Indirect-Fired Water Heaters – Series 3 Read this page first Hazard definitions The following defined terms are used throughout this manual to bring attention to the pres- ence of hazards of various risk levels, or to important information concerning the life of the product. Indicates presence of hazards that will cause severe personal injury, death or substantial property damage. Indicates presence of hazards that can cause severe personal injury, death or substantial property damage. Indicates presence of hazards that will or can cause minor personal injury or property damage. Indicates special instructions on installation, operation or maintenance that are important but not related to personal injury or property damage. Read all instructions before installing. Failure to follow all instructions in proper order can cause 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. -
Page 3: Table Of Contents
Manual • Installation Contents A. G Part Number PLUS-E017-A/1206 • Start-Up • Usage Overview This manual contains six sections, A through F. Sections A, E apply to or 80; and PLUS 100, 110, or 119 water heater installations, regardless of the boiler used. -
Page 4: Zoning With Zone Valves
PLUS LINE Indirect-Fired Water Heaters – Series 3 Contents c. B continued Balancing ... 22 Components required ... 22 Connecting to the water heater ... 22 fired Boiler ApplicAtions B1. Install system water piping System water piping methods ... 25 Boiler circulator ... 25 Sizing space heating system piping ... - Page 5 Wiring requirements — Zone Valves ... 47 Boiler models requiring domestic priority with GOLD Plus 30 ... 47 Zoning with pumps: Zoning with Weil-McLain circulator zone controller (WMCR) • Weil-McLain circulator zone controller (Figure 30) ... 48 Other options for for zoning with pumps • Using priority zone pump (Figure 31) ... 49 • Using pump relays •...
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Page 6: G Eneral Installation ( All Water Heaters )
PLUS LINE Indirect-Fired Water Heaters – Series 3 Codes Location Recommended clearances Figure 1 Clearance recommendations Pre-installation Installation must conform with instructions in this manual and, where applicable: • local, state, provincial, and national codes, laws, regulations and ordinances. • in Canada — B19.1 or B19.2 Installation Code. PLUS water heaters are exempt from ASME Section VIII, Division 1 Code construction per Interpretation VIII-1-8-1. Check with local codes for applicability. Where recommendations in this manual differ from local or national codes, local or national codes take precedence. This water heater is not intended for outdoor installation. Select a convenient location for water heater, based on domestic and boiler piping hook-ups. Keeping the distance between boiler and water heater short will: • reduce piping heat loss. • provide minimum friction loss. Install water heater so if 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. This product is designed for vertical installation only. Installation location must provide adequate clearances for servicing and proper operation of the water heater. GOLD Plus 30/40/60/80 or • Zero clearance is permissible to either side of water heater, but Instruction label or other labels may be hidden. -
Page 7: Operating Restrictions
Manual • Installation Operating restrictions Code restrictions Part Number PLUS-E017-A/1206 • Start-Up • Usage Pre-installation • Maximum domestic hot water temperature ( operational requirements • 10°F for GOLD Plus 0/0/0/80 or • 190°F for PLUS 100/110/119. • Maximum boiler water temperature — 210°F. • Maximum working pressure for inner (domestic water) tank — 10 psig. • Maximum working pressure for outer (boiler water) tank — psig. • pH and chloride limits for water heaters are: • chloride — less than 80 mg/l. • pH — above and less than 8. National Standard Plumbing Code Single wall heat exchanger in water heater complies with National Standard Plumbing Code, provided that: • boiler water (including additives) is practically non-toxic, having toxicity rating or class... -
Page 8: A2. Water Heater Piping
PLUS LINE Indirect-Fired Water Heaters – Series 3 Temperature & pressure (T & P) relief valve Air vent Water heater piping To reduce risk of excessive pressures and temperatures in water heater, install temperature and pressure protective equipment required by local codes, but no less than a combination temperature and pressure relief valve certified by a nationally recognized testing laboratory that main- tains periodic inspection of production of listed equipment or materials, as meeting the requirements for Relief Valves and Automatic Gas Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be marked with a maximum working pressure of the water heater. 1. Size T&P relief valve by the following specifications, unless they conflict with local codes: • GOLD Plus 0/0/0/80 or 100,000 BTU/hr, with a long element. Set to relieve at 10 psi. (Watts model 100XL-8... -
Page 9: Piping Drawings And Drain Valve Information
Manual • Installation Water heater piping Figure 2 OPTION 1 Piping — GOLD Plus 30/40/60/80 or Plus 40/60/80 (See Figure 3, page 10, for Option 2, required for Massachusetts) An expansion tank may be required on the DHW piping. See Thermal expansion WARNING on page 1. Failure to comply could result in severe personal injury, death or substantial property damage. When the water supply pressure is higher than 0 psig, install a pressure-reducing valve on the cold water supply line to prevent leakage from the T & P relief valve. - Page 10 PLUS LINE Indirect-Fired Water Heaters – Series 3 Water heater piping Figure 3 OPTION 2 Piping — Models 30/40/60/80 or Plus 40/60/80 (Required for Commonwealth of Massachusetts) An expansion tank may be required on the DHW piping. See Thermal expan- sion WARNING on page 1. Failure to comply could result in severe personal injury, death or substantial property damage. When the water supply pressure is higher than 0 psig, install a pressure-reducing valve on the cold water supply line to prevent leakage from the T & P relief valve.
- Page 11 Manual • Installation Water heater piping Figure 4 OPTION 1 Piping — PLUS 100/110/119 (See Figure 5, page 12, for OPTION 2, required for Massachusetts) An expansion tank may be required on the DHW piping. See Thermal expan- sion WARNING on page 1. Failure to comply could result in severe personal injury, death or substantial property damage. When the water supply pressure is higher than 0 psig, install a pressure-reducing valve on the cold water supply line to prevent leakage from the T & P relief valve. Drain valve PLUS 100/110/119 Option 1 Part Number PLUS-E017-A/1206...
- Page 12 PLUS LINE Indirect-Fired Water Heaters – Series 3 Water heater piping Figure 5 OPTION 2 Piping — PLUS 100/110/119 (Required for Commonwealth of Massachusetts) An expansion tank may be required on the DHW piping. See Thermal expan- WARNING sion on page 1. Failure to comply could result in severe personal injury, death or substantial property damage. When the water supply pressure is higher than 0 psig, install a pressure-reducing valve on the cold water supply line to prevent leakage from the T & P relief valve. Drain valve PLUS 100/110/119 Option 2 continued...
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Page 13: Thermal Expansion
Manual • Installation Thermal expansion Water hammer General piping information Table 1 Piping (Inches NPT) Part Number PLUS-E017-A/1206 • Start-Up • Usage Water heater piping If a backflow preventer, check valve, or pressure 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 repeat- edly 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 expansion. Refer to expansion tank manufacturer’s instructions for proper sizing. Failure to follow the above could result in severe personal injury, death or substantial property damage. Dishwashers, clothes washers, and fast-closing positive shutoff valves incorporated in the system all contribute to creating water shock. Install a water hammer arrester to prevent damage to pipes and appliances. See control manufacturer’s instructions for application and installation. • For domestic water piping, see pages 8 through 12. • See pages 22–2, for domestic water recirculation piping. • See Table 1 for piping connections: • All plumbing must meet or exceed all local, state and national plumbing codes. -
Page 14: Domestic Water Piping
PLUS LINE Indirect-Fired Water Heaters – Series 3 Domestic water piping Boiler water Water heater piping • Union on domestic hot water outlet should be piped at a higher elevation than domestic water drain valve. This will make draining water heater easier. • Install unions for easy removal of water heater. 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. • If copper pipe is used for domestic water connections, first solder pipe to a threaded adapter, and then screw adapter into cold water inlet on top of water heater. Inlet contains an internal plastic dip tube rated at 20°F, which can be damaged by heat from soldering. • When the supply pressure is higher than 0 psig, install a pressure reducing valve on cold water supply line to prevent water loss through T&P relief valve. • If water heater will replace tankless coil in boiler,` disconnect piping to coil or remove coil from boiler and replace with a cover plate. Allow water to drain from coil. Do not plug tankless coil. Plugging tankless coil inlet and outlet will result in severe personal injury, death or substantial property damage. • 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. -
Page 15: A3. Water Heater Wiring
Manual • Installation Water heater thermostat connection Figure 6 Thermostat connection Part Number PLUS-E017-A/1206 • Start-Up • Usage Water heater wiring PLUS-Line indirect water heaters utilize a snap-set connector for easy wiring between water heater thermostat and boiler controls (also see Section B or D). See Figure , below. Terminal 1 of the snap-set is the normally-open contact; terminal 2 is the normally-closed contact; terminal C is common. • Maintenance • Parts... -
Page 16: A4. Water Heater Start-Up
PLUS LINE Indirect-Fired Water Heaters – Series 3 Filling the inner (domestic water) tank Filling the outer (boiler water) tank Water heater start-up • Inner tank must be completely filled and pressurized before pres- surizing outer tank. • Never use water heater unless inner and outer tanks are completely filled with water. 1. Close domestic water drain valve. 2. Open domestic water isolation valves for water heater. . Vent air from inner (domestic water) tank by opening nearest hot water faucet. Fill domestic water tank completely by allowing water to run until there is a constant flow of water. . Close hot water faucet. • Inner tank must be completely filled and pressurized before pres- surizing outer tank. -
Page 17: Start-Up Checklist
Manual • Installation Start-up checklist Part Number PLUS-E017-A/1206 • Start-Up • Usage Water heater start-up ❏ Long element T&P relief valve is properly installed and drain discharge is directed away from all persons. ❏ Both inner and outer tanks are filled with water. ❏ All air has been bled from both domestic and boiler water systems. ❏ Automatic air vent is installed and cap is unscrewed one full turn. ❏ Cold and hot water lines are correctly connected to domestic water system. ❏ Supply and return piping from boiler is correctly connected to water heater. ❏ All wiring is installed correctly. ❏ Thermostat on water heater is set according to system requirements. See pages 18–19. ❏ Boiler and water heater are operating properly. ❏ Fittings and piping have been checked for leaks. ❏ Installer has reviewed the following sections with system maintainer: • Water Heater Start-Up • Adjusting Water Heater Temperature • Water Heater Maintenance •... -
Page 18: A5. Adjusting Water Heater Temperature
PLUS LINE Indirect-Fired Water Heaters – Series 3 Adjusting water heater temperature General notes Hot Water Can Scald! • Water temperature over 12°F can cause severe burns instantly, or death from scalds. • Feel water before bathing or showering. • Consumer Product Safety Commission and some states recommend temperature settings of 10°F or less. Setting thermostat higher than 10°F setting will increase risk of scald injury and can cause severe personal injury or death. -
Page 19: Setting The Thermostat - Gold Plus 30/40/60/80 Or Plus 40/60/80
Manual • Installation Adjusting water heater temperature 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. Setting the thermostat GOLD Plus 30/40/60/80 Plus 40/60/80 Water heater thermostat is factory set to its lowest tem- perature. The arrowhead indicator preferred starting point for setting temperature. This may or may not be suitable for your needs. -
Page 20: A6. Water Heater Maintenance
PLUS LINE Indirect-Fired Water Heaters – Series 3 Maintenance schedule – annual service technician Maintenance schedule – monthly homeowner Water heater maintenance Annual service by qualified service technician to include: • Any procedures required by local codes. • Check air vent operation. • Verify system pressure. Air venting procedure may require adding water to bring system up to pressure, typically 12 psig. • Manually operate T&P relief valve at least once a year. This will release some hot water. Before operating T&P relief valve, make sure no one is in front of or around T&P relief valve discharge piping. Hot discharge water can... -
Page 21: Filling
Manual • Installation Filling Draining Draining inner (domestic water) tank Draining outer (boiler water) tank Part Number PLUS-E017-A/1206 • Start-Up • Usage Water heater maintenance Filling the Inner (Domestic Water) Tank See on page 1. Drain water heater if it will be shut off and exposed to freezing temperatures. Freezing water will expand and may damage water heater. If boiler water contains sufficient antifreeze, then only the domestic water needs to be drained. -
Page 22: Maintaining Domestic Water Temperature In The Supply Piping
PLUS LINE Indirect-Fired Water Heaters – Series 3 Recirculation and heat tracing Maintaining domestic water temperature in the supply piping Two options are available to maintain supply temperature available at or near the fixtures on storage water heating systems: · Recirculation 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 fixture exceeds 100 feet or the time lag for hot water to reach a fixture(s) exceeds 0 seconds. Consult local codes and American Society of Plumbing Engineers (ASPE) Domestic Water Heating Design... - Page 23 Manual • Installation Recirculation components Figure 10 Recirculation connection at water heater Components Circulator — Little flow is required to maintain a temperature in the piping. Size of circulator depends on minimum flow requirements of the tempering valve. Minimum flow rates of the tempering valve must be maintained. Aquastat —...
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Page 24: Gas
PLUS LINE Indirect-Fired Water Heaters – Series 3 Gas-fired boiler applications Overview Follow the guidelines in this section to install PLUS indirect water heaters. Install the domestic water piping and water heater following the guidelines of Section A. See Sections C and D for other boiler applications. B1. Install system water piping System water piping methods ... -
Page 25: Install System Water Piping
Install system water piping System water piping methods All piping methods shown in this manual use primary/secondary connection to the boiler loop. These designs ensure proper flow through the the most efficient and reliable operation of the boiler and the heating system. For other piping methods, consult your local Weil-McLain representative or refer to separate Wall-mounted boilers — Piping can exit bottom of boiler enclosure. See separate wall-mounting instructions for details. Expansion tank and make-up water 1. Ensure expansion tank size will handle boiler and system water volume and temperature. Allow gallons for the boiler and its piping. -
Page 26: Zoning With Zone Valves
PLUS LINE Indirect-Fired Water Heaters – Series 3 Install system water piping Zoning with zone valves 1. Connect boiler to system as shown in Figure 12 when zone valve zoning. The primary/secondary piping shown ensures the boiler loop will have suf- ficient flow. It also avoids applying the high head of the boiler circulator to the zone valves. 2. Connect water heater (domestic hot water) pip- ing to indirect storage water heater as shown in Section A of this manual. -
Page 27: Zoning With Circulators
Manual • Installation Install system water piping Zoning with circulators 1. Connect boiler to system as shown in Figure 1 when circulator zoning. The boiler circulator can- not be used for a zone. It must supply only the boiler loop. 2. Install a separate circulator for each zone. . Connect water heater (domestic hot water) pip- ing to indirect storage water heater as shown in Section A of this manual. -
Page 28: B2. Install Boiler-To-Water Heater Piping
PLUS LINE Indirect-Fired Water Heaters – Series 3 Install boiler-to-water heater piping Combined space heating/water heating applications 1. Figure 1 shows recommended piping between boiler and PLUS water heater. All show direct connection of the water heater piping to the boiler because the boiler circulator shuts down during water heater operation. 2. Table , page 29, uses the recommended flow rates for the PLUS water heater and minimum flow rates for the Gas boiler to provide recommended water heater piping and circulator sizing. If using another circulator, verify it is at least equal to the Taco selection given in Table , page 29. For general information on head loss through boiler and boiler-to-water heater piping, refer to the Manual. - Page 29 Manual • Installation The following ratings are for Ultra Gas boilers only, with supply water temperature at 190°F. For boilers other than Ultra Gas, see page for ratings. Table 3 Combined space heating/water heating (see Notes) Boiler PLUS 1st Hour Boiler Head losses, Feet w.c. Model rating, GPH piping Rec. 115°F 140°F Boiler Heater Piping TOTAL size Ultra- 1" Ultra- 1" 1" 1¼" Ultra- 10.8 1¼"...
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Page 30: B3. Field Wiring
PLUS LINE Indirect-Fired Water Heaters – Series 3 Field wiring — ELECTRICAL SHOCK HAZARD — For your safety, turn off electrical power supply at service entrance panel before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death. Wiring must be N.E.C. Class 1. If original wiring as supplied with boiler must be replaced, use only type 10 °C wire or equivalent. Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 0 – latest edition. -
Page 31: Wiring A System Circulator
Manual • Installation Field wiring — Wiring a system circulator 1. For combined systems, to activate a system circu- lator when the Boiler circulator operates, wire as shown at bottom of Figure 1, page 0. 2. You must install a relay as shown. DO NOT wire in parallel with the Boiler circulator. See Figure 1. Routing line voltage wiring 1. Route line voltage connections to the jacket open- ings shown in Figure 18. Low voltage connections (Fig. 18) 1. Connect low voltage wiring to low voltage termi- nal strip (Figure 19, page 2, item 1) as shown in Figure 19 and the boiler wiring diagram. 2. Route all low voltage wires through grommeted jacket opening to right of low voltage terminal strip, as shown in Figure 18. - Page 32 PLUS LINE Indirect-Fired Water Heaters – Series 3 Field wiring — Figure 19 Summer/winter switch (item ) — Install a summer/winter switch, if desired, to disable the boiler (space heating) circulator during non-heating months. Connect switch across the outdoor sensor terminals. When switch closes, the boiler circulator is disabled and the boiler operates only on call for DHW heating. Gas boilers only Low voltage field wiring connections Part Number PLUS-E017-A/1206 (continued)
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Page 33: Follow Boiler Manual
Manual • Installation Start-up — Follow boiler manual 1. Follow all procedures in the to start up and verify operation of the boiler. Set space heating operation Verify space heating mode 1. Press the “Mode” button until the display shows “Para.” This is the parameter mode. 2. Press the “Step” button until the display first digit shows “.” . The last digit must show “1.” If any other number displays, press the “+” button until “1” shows in the right-hand digit. Press the “Store” button to save this setting. Set space heating target temperature 1. Press the the display first digit shows “.” The right digits show the outlet water temperature setting. -
Page 34: Verify Water Heater Operation
PLUS LINE Indirect-Fired Water Heaters – Series 3 Start-up — [3180] (burner on, space heating) Once flame is proven and stable, the burner turns down to low fire for ap- proximately 2 minutes. • After this low fire period, the burner is allowed to modulate. Firing rate depends on actual outlet water temperature versus target temperature. . Allow boiler to bring water temperature to target temperature. [6180] (target temperature reached) The burner will shut down. The blower will run in postpurge (see below), then turn off. The boiler circulator continues to run as long as there is a call for heat. . Lower room thermostat to stop call for heat. [1180] (postpurge) When the room thermostat is satis- fied (call for heat ended), the burner turns off. The blower will continue for a 1-second postpurge, then... -
Page 35: Boiler-Side Piping
Manual • Installation Boiler-side piping Part Number PLUS-E017-A/1206 • Start-Up • Usage (except This section provides suggested boiler-side and system piping for boilers other than Gas-fired boilers ( B for see Section for: • single or multiple water heaters • zoned systems using zone valves or circulators • dedicated boiler applications • recirculation piping Make sure to apply an appropriate control wiring method. Each piping diagram lists compatible control wiring diagrams in Section Zoning with pumps GOLD PLUS 30/40/60/80 or Two-pipe system piping — Figure 20... 36 Primary/secondary piping — Figure 21 ... 37 PLUS 100/110/119 Primary/secondary piping —... -
Page 36: Wiring Options
• Figure 33, page 51 — Pump relays without domestic priority Notes (except 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. Gas) continued Part Number PLUS-E017-A/1206... -
Page 37: Primary/Secondary Piping - Figure 21
33, page 51 — Pump relays without domestic priority Notes Part Number PLUS-E017-A/1206 • Start-Up • Usage (except 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. • Maintenance • Parts Gas) -
Page 38: Primary/Secondary Piping - Figure 22
• Figure 42, page 60 — Pump relays and 3-way priority valve and priority relay Notes (except 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. Gas) continued Part Number PLUS-E017-A/1206... - Page 39 2-way zone valve on water heater circuit Notes Part Number PLUS-E017-A/1206 • Start-Up • Usage (except 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. • Maintenance • Parts Gas)
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Page 40: Figure 24
Plus 40/60/80). • Locate flow/check valve as close as possible to water heater boiler side connections — to reduce heat loss between cycles. Notes (except 1. These drawings are conceptual only. They show representative piping components and layout. Weil-McLain does not represent that the drawings meet any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawings. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. . Recommended piping for PLUS 100/110/119 water heaters used in residential applica- tions. Gas) continued Part Number PLUS-E017-A/1206... -
Page 41: Applications
— to reduce heat loss between cycles. Notes Part Number PLUS-E017-A/1206 • Start-Up • Usage (except 1. These drawings are conceptual only. They show representative piping components and layout. Weil-McLain does not represent that the drawings meet any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawings. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. . Recommended piping for GOLD Plus 0/0/0/80 water heaters used in commercial applications. • Maintenance • Parts Gas) continued... - Page 42 Notes Figure 27 Details for Figure 28, page 43 — alternate water heater piping and Easy-Fit ® Manifold detail (except 1. The drawings on this page are conceptual only. They show representative piping components and layout. Weil-McLain does not represent that these drawings meet any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Any one PLUS tank thermostat may be utilized to control heater temperature. . Install automatic mixing valve at either the system hot water connection or at each water heater. . See pages 2- for additional recirculation information and piping detail. Gas) continued Part Number PLUS-E017-A/1206...
- Page 43 Multiple water heaters and dedicated multiple boilers — boiler water piping (see legend and details in Figure 26, page 42) Notes Part Number PLUS-E017-A/1206 • Start-Up • Usage (except 1. This drawing is conceptual only. It shows representative piping components and layout. Weil-McLain does not represent that this drawing meets any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawing. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. • Maintenance • Parts Gas) continued...
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Page 44: Connecting Water Heater To Steam Boiler
PLUS LINE Indirect-Fired Water Heaters – Series 3 Boiler-side piping Connecting water heater to steam boiler When designing steam and domestic hot water sys- tems, there are some key issues that must be taken into consideration during the initial design phase. By designing the system properly from the start, you can avoid problems and have a hot water loop in a steam boiler system. Special considerations: • Keep the loop temperature below the flash point. - Page 45 (cavitation) in the circulator. Slowly open valve until temperature gauge 8 reads 200°F. Lock or remove the handle from valve after adjusting. Notes Part Number PLUS-E017-A/1206 • Start-Up • Usage (except 1. These drawings are conceptual only. They show representative piping components and layout. Weil-McLain does not represent that the drawings meet any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawings. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. See Weil-McLain installation instructions for specific details on installing the boiler. • Maintenance • Parts Gas) continued...
- Page 46 Boiler models requiring domestic priority with GOLD Plus 30 ... 47 with pumps Zoning with Weil-McLain circulator zone controller (WMCR) • Weil-McLain circulator zone controller ... 48 Other options for for zoning with pumps • Using priority zone pump ... 49 • Using pump relays • Domestic priority with priority relay ... 50 •...
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Page 47: Iring Requirements
Manual • Installation Boiler-side wiring & controls Wiring requirements Part Number PLUS-E017-A/1206 • Start-Up • Usage Electrical shock hazard. Can cause severe personal injury, death or substantial property damage. Disconnect power before installing and/or servicing. 1. All wiring must be a minimum of 18 gauge and installed in accordance with: • 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. 2. If original wire as supplied with appliance must be replaced, Type 90° C or its equivalent must be used. . Refer to control component instructions packed with boiler for application information. . An optional service switch may be installed in water heater electrical 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. . All electrical contacts are shown with no power applied - off shelf condition. Circulators . Size priority relay for total amp draw of all circulators. Zone Valves . Size transformer for maximum load of all zone valves. -
Page 48: Oning With Pumps
System piping — Apply this wiring to systems • Figure 20, page 36 • Figure 21, page 37 Notes Domestic water priority with Weil-McLain WMCR Circulator Zone Controller 1. These drawings are conceptual only. They show representative piping components and layout. Weil-McLain does not represent that the drawings meet any particular mechanical or building codes. The installer is responsible for inclusion of all required safety devices, or other miscellaneous piping hardware not shown on drawings. The installer is responsible for proper sizing/selection of all hardware shown on this diagram. 2. Follow component manufacturer’s instructions for installation of all items shown. . See Weil-McLain installation instructions for specific details on installing the boiler. (except Gas) -
Page 49: Using Priority Zone Pump
Boiler-side wiring & controls Figure 31 Typical wiring • Zoning with pumps • Using priority zone pump • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping —... -
Page 50: Using Pump Relays
Typical wiring: • Zoning with pumps • Using pump relays • Domestic priority with priority relay • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 51: No Domestic Priority
Figure 33 Typical wiring: • Zoning with pumps • Using pump relays • No domestic priority • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 35. System piping — Apply this wiring to systems •... -
Page 52: Zoning With Weil-Mclain Zone Valve Controller (Wmzv)
• Figure 23, page 39 (using 2-way water heater zone valve and no priority valve) Install all zone valves per valve manufacturer’s instructions. Domestic water priority with Weil-McLain WMZV Zone Valve Controller (except Gas) continued Part Number PLUS-E017-A/1206... -
Page 53: Typical Wiring
Boiler-side wiring & controls Figure 35 Typical wiring: • Zoning with 4-wire zone valves • No domestic priority • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 54: No Domestic Priority
Boiler-side wiring & controls Figure 36 Typical wiring: • Zoning with 3-wire zone valves • No domestic priority • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 55: Plus 40/60/80
• With OR without domestic priority • GOLD Plus 30/40/60/80 or Plus 40/60/80 • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 56: With Or Without Priority
• With OR without domestic priority • GOLD Plus 30/40/60/80 or Plus 40/60/80 • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 57: With Domestic Priority
Typical wiring: • Zoning with zone valves • With domestic priority • PLUS 100/110/119 only • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 58: With Domestic Priority
4-wire zone valves • With domestic priority using 2-way priority valve • PLUS 100/110/119 only • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 59: With Domestic Priority Using 2-Way Priority Valve
Typical wiring: • Zoning with 3-wire zone valves • With domestic priority using 2-way priority valve • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 60: Domestic Priority With 3-Way Priority Valve & Priority Relay
• Pump relays • Domestic priority with 3- way priority valve and priority relay • Also refer to Weil-McLain Boiler Zone Wiring Guide for further details. • Refer to Wiring requirements on page 47. System piping — Apply this wiring to systems •... -
Page 61: E. R Eplacement Parts
Manual • Installation Replacement parts — Series 3 only Part Number PLUS-E017-A/1206 • Start-Up • Usage A. GOLD Plus 30, 40, 60 or 80 Plus 40, 60 or 80 ... 50 B. PLUS 100, 110 or 119 ... 52 • Maintenance • Parts... -
Page 62: Plus Line Indirect-Fired Water Heaters – Series
PLUS LINE Indirect-Fired Water Heaters – Series 3 Replacement parts continued GOLD Plus 30/40/60/80 or PLUS 40/60/80 Series 3 Part Number PLUS-E017-A/1206... -
Page 63: Replacement Parts
Drywell replacement kit, Gold Plus 60, Ultra PLUS 60 Drywell replacement kit, Gold Plus 80, Ultra PLUS 80 Part Number PLUS-E017-A/1206 • Start-Up • Usage • Maintenance continued Size • Parts Manufacturer Weil-McLain Part Number Weil-McLain 633-900-130 Weil-McLain 633-900-117 ¾" Weil-McLain 633-900-118 ¾"... -
Page 64: Plus 100/110/119
PLUS LINE Indirect-Fired Water Heaters – Series 3 Replacement parts continued PLUS 100/110/119 Series 3 Part Number PLUS-E017-A/1206... -
Page 65: Plus 100/110/119
Dip Tube “O” Ring Drywell Replacement Kit for 100/110/119 Part Number PLUS-E017-A/1206 • Start-Up • Usage • Maintenance continued Replacement parts — PLUS 100/110/119 Series 3 100/110 • Parts Weil-McLain Part Size Manufacturer Number Weil-McLain 635-100-010 1½" Weil-McLain 633-900-115 Weil-McLain... -
Page 66: Water Heater Dimensions
PLUS LINE Indirect-Fired Water Heaters – Series 3 Water heater dimensions Dimensions — PLUS-Line indirect water heaters, Series 3 PLUS-Line Indirect-Fired Water Heaters — Series 3 Water Storage Heating surface Heater Model Boiler side side Gallons Gallons Sq. Feet GOLD Plus 30 GOLD Plus 40 Ultra Plus 40 GOLD Plus 60... -
Page 67: Performance Ratings
Manual • Installation Water heater performance ratings For water heater to achieve the rated performance below: Boiler water must be supplied to the water heater at at least 200°F, and the boiler water flow rate must be no less than given in the tables below. For applications, with supply water at 190°F, see the ratings in Section B of this manual) Boiler First Hour Rating Capacity (GPH) — Boiler Water Supply at 200°F / Domestic Water from 50°F to 140°F GOLD Boiler GOLD/ Boiler Heating Water Water Plus Ultra Capacity Plus Minimum Minimum Boiler... -
Page 68: Warranty
Weil-McLain will provide replacement of such defective parts. Second Through Tenth Year — (Residential & Commercial Water/Steam) Weil-McLain warrants that the cast iron sections of its water and steam boilers are free from defects in material and workmanship from the date of installation for the second through the tenth year.
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