Weil-McLain PLUS LINE PLUS-E017-A/1206 manual

P ar t Number PLUS-E017-A/1206 User — Read important user safety information found on pages 2, 18, 19 and 20. Installation and service should only be performed by a qualified serv ice technician. R etain this manual for fu ture refe rence. P lus 40/60/80 Plus 100/110/119 • Installation • Star tup • Maintenance • P arts Manual This manua [...]

2 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Hot W ater Can Scald! • W at er heated to temperatur e for clothes washing, dish washing and other sanitizing needs can scald and cause permanent injur y . • Children, elderly , and infirm or physically handicapped persons are more likely to be permanently i[...]

P ar t Number PLUS-E017-A/1206 3 Manual • Installation • Start-Up • Usage • Maintenance • Parts Overview This manual contains six sections, A through F. Sections A, E and F apply to ALL GOLD Plus 30, 40, 60 or 80; PLUS 40, 60, or 80; and PLUS 100, 110, or 119 water heater installations, regardless of the boiler used. Section A gives guide[...]

4 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Balancing .................................................................................................................... 22 Components required ................................................................................................ 22 Connecting to[...]

P ar t Number PLUS-E017-A/1206 5 Manual • Installation • Start-Up • Usage • Maintenance • Parts PLUS 100/110/119 Figure 25 ..................................................................................................................... 41 Multiple water heater applications Multiple water heaters – water heater piping — Figures 26[...]

6 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Codes Installation must co nform with inst ructions in this manual and, where applicable: • local, state, pr ovincial, and national c odes, laws, regulations and ordinances. • in Canada — B149.1 or B149.2 Installation Code. PL US water heaters are ex empt f[...]

P ar t Number PLUS-E017-A/1206 7 Manual • Installation • Start-Up • Usage • Maintenance • Parts Operating restrictions • Maximum d omestic hot wate r temperature ( Use only for special high-temperature operational requirements ): • 160°F for GOLD Plus 30/40/60/80 or Plus 40/60/80. • 190°F for PL US 100/110/119. • Maximum boiler [...]

8 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 T emperature & pressure (T & P) relief v alve Air vent The boiler-side piping must be equipped w ith a diaphr agm- or bladder- ty pe expansion tank, NOT a c losed-ty pe expansion tank. 1. Remo ve plastic shipping cap fr om 1/2” NPT pipe fitting on top [...]

P ar t Number PLUS-E017-A/1206 9 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 2 Piping — OPTION 1 GOLD Plus 30/40/60/80 or Plus 40/60/80 (See Figure 3, page 10, f or Option 2, required f or Massachusetts) Drain v alve GOLD Plus 30/40/60/80 Option 1 Apply the following and Figure 2 to wate r heaters other than th[...]

10 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 W ater heater piping continued A2 Figure 3 Piping — OPTION 2 Models 30/40/60/80 or Plus 40/60/80 (Required f or Commonwealth of Massachusetts) Drain v alve GOLD Plus 30/40/60/80 or Plus 40/60/80 Option 2 Apply the following and Figure 3 t o water heate rs inst[...]

P ar t Number PLUS-E017-A/1206 11 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 4 Piping — OPTION 1 PLUS 100/110/119 (See Figure 5, page 12, f or OPTION 2, required f or Massachusetts) Drain v alve PLUS 100/110/119 Option 1 Apply the following and Figure 4 to wate r heaters other than those installed in Massach u[...]

12 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Figure 5 Piping — OPTION 2 PLUS 100/110/119 (Required f or Commonwealth of Massachusetts) Drain v alve PLUS 100/110/119 Option 2 Apply the following and Figure 5 t o water heate rs installed in Massachusetts. The dr ain valv e is mounted in the A UX tapping on[...]

P ar t Number PLUS-E017-A/1206 13 Manual • Installation • Start-Up • Usage • Maintenance • Parts General piping inf ormation • For domestic wate r piping, see pages 8 thr ough 12. • See pages 22–23, for d omestic water recir culation piping. • See T able 1 for piping connections: • All plumbing must meet or exc eed all local, st[...]

14 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Domestic water piping • U nion on domestic hot water outlet should be piped at a hig her elevation than domestic water drain valv e. This wil l make draining wate r heater easier . • Install unions for easy remo val of water heat er . U se dielectric unio ns[...]

P ar t Number PLUS-E017-A/1206 15 Manual • Installation • Start-Up • Usage • Maintenance • Parts W ater heater thermostat connection PL US-Line indirect water heaters utilize a snap-set connector for easy w iring between water heater thermostat and boiler co ntrols (also see Section B or D). See Figure 6, below . Figure 6 Thermostat conne[...]

16 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. Close boiler water drain valv e at boiler water outlet of water heater . 2. Open water heater’ s boiler water isolation valv es. 3. Allow air t o escap e from outer (boiler water) tank by opening cap “ A ” (se e Figure 7) on automatic air v ent, located[...]

P ar t Number PLUS-E017-A/1206 17 Manual • Installation • Start-Up • Usage • Maintenance • Parts Star t-up chec klist ❏ Long element T&P r elief valve is pr operly installed and dr ain discharge is directed awa y from all persons. ❏ Both inner and outer tanks ar e filled w ith water . ❏ All air has been bled from both [...]

18 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Hot W ater Can Scald! • W ater temperature ov er 125°F can cause severe burns instantly , or death fr om scalds. • Feel wate r before bathing or sho wering. • Consum er Product Safe ty Commiss ion an d some state s recomm end tem per atu re set ting s of [...]

P ar t Number PLUS-E017-A/1206 19 Manual • Installation • Start-Up • Usage • Maintenance • Parts Studies hav e indicated that dangerous bacteria, including legionella pneumophila, can form in the potable water distr ibution system if certain minimum water temperatures are not maintained. Contact your local health department for more infor[...]

20 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 W ater heater maintenance A6 Maintenance schedule – ann ual service technician Annual service by qualified service technician to include: • Any pr ocedures r equired b y local codes. • Check air vent operation. • V erify system pressure. Air venting pro[...]

P ar t Number PLUS-E017-A/1206 21 Manual • Installation • Start-Up • Usage • Maintenance • Parts Filling See Filling the Inner (Domestic Water) Tank , and Filling the Outer (Boiler Water) Tank , on page 16. Draining Drain water heater if it will be shut off and exposed to freezing temperatur es. F reezing water will expand and may damage [...]

22 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 T able 2 Time lag to obtain hot water at fixture f or branch lengths of 10 and 25 f eet (ASPE Domestic W ater Heating Design Manual ) Time in seconds required to get hot water at fixture (from ASPE) Fixture flow r ate (GPM) - 0.5 1.5 2.5 4.0 Piping length (feet[...]

P ar t Number PLUS-E017-A/1206 23 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 10 Recirculation connection at water heater Figure 9 Recirculation components Components 1 Cir culato r — Little flo w is req uired to maintain a tempera ture in the piping. Size of cir culat or depends on minim um flo w r equir eme[...]

24 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 B Gas-fir ed boiler applications Overview Follow the guidelines in this section to install Gas-fired boilers with PLUS or PLUS indirect water heaters. Install the domestic water piping and water heater following the guidelines of Section A. See Sections C and [...]

P ar t Number PLUS-E017-A/1206 25 Manual • Installation • Start-Up • Usage • Maintenance • Parts Install system water piping (space heating) Figure 11 Expansion tank piping B1 Gas System water piping methods All pip ing met hods sho wn in this manua l use primary/sec onda ry c onn ection to the boiler loop . These designs ensure pr oper ?[...]

26 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Install system water piping (space heating) (continued) Figure 12 Zone valv e z oning plus optional water heater piping Zoning with zone valves 1. Connec t boiler to system as shown in Figu re 12 when zone val ve zoning. The pr imary/secondar y piping shown ensu[...]

P ar t Number PLUS-E017-A/1206 27 Manual • Installation • Start-Up • Usage • Maintenance • Parts Install system water piping (space heating) (continued) Figure 13 Circulator zoning plus optional w ater heater piping Zoning with cir culators 1. Connec t boiler to system as shown in Figu re 13 when circulat or zoning. The boile r circulat o[...]

28 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Install boiler -to-water heater piping Combined space heating/water heating applications 1. Figure 14 sho ws r ecommended piping between Gas boiler and PL US water heater . All show direct c onnection of the water heat er piping to the boiler because the boiler [...]

P ar t Number PLUS-E017-A/1206 29 Manual • Installation • Start-Up • Usage • Maintenance • Parts T able 3 Combined space heating/water heating (see Notes) T able 4 De d i ca te d w at e r - he a t i n g, u s in g c i rc ul at or s up pl ie d w it h b o il er (s e e N ot es ) Boiler PLUS Model 1st Hour rating, GPH Boiler piping Head losses[...]

30 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 ELECTRICAL SHOCK HAZARD — For yo ur s a fe t y , tu r n o f f el ec t r i ca l power supply at ser vice entrance panel befor e making any electr ical con nections to avo id p ossible elect ric shock hazard. Fail ure to do so can cause sever e personal injury o[...]

P ar t Number PLUS-E017-A/1206 31 Manual • Installation • Start-Up • Usage • Maintenance • Parts Wiring a system cir culator 1. For combined systems, to ac tivate a system circu- lator when the Boiler circulator operates, w ire as shown at bottom of Figure 17, pag e 30. 2. Y ou must install a relay as shown. DO NOT w ire in parallel with [...]

32 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Field wiring — Gas boilers only (continued) Figure 19 Low v oltage field wiring connections Summer/winter switch (item 7) — Install a summer/winter sw itch, if desired, to disable the boiler (space heating) circulato r during non-heating months. Connect swi[...]

P ar t Number PLUS-E017-A/1206 33 Manual • Installation • Start-Up • Usage • Maintenance • Parts Start-up — Gas boilers only B4 Gas Follow boiler manual 1. Fo llo w all pr oc ed ur es in the Gas bo ile r manu al to start up and verify operation of the boiler . Set space heating operation V erify space heating mode 1. Press the “M ode [...]

34 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Start-up — Gas boilers only (continued) B4 Gas [ 3180 ] ( burner on, space heat ing ) Once flame is prov en and stable, the burner turns down to low fire for ap - pro ximately 2 minu tes. • After this low fi re per iod, the burner is allowed to modulate. [...]

P ar t Number PLUS-E017-A/1206 35 Manual • Installation • Start-Up • Usage • Maintenance • Parts Boiler -side piping (except Gas) This sect ion provides suggested boiler-side and system piping for boiler s other than Gas-fired boilers ( see Se ction B for Gas applications). Y ou wil l find suggested piping for: • single or multiple wa[...]

36 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Figure 20 GOLD Plus 30/40/60/80 Plus 40/60/80 • Zoning with pumps • Place pumps at beginnings of zones . Placing them at the ends of zones could result in heating idle zones . • Size manif ol d pip ing fo r tota l flo w of all zone pumps . • Locate flow[...]

P ar t Number PLUS-E017-A/1206 37 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 21 GOLD Plus 30/40/60/80 Plus 40/60/80 • Zoning with pumps • Primar y/secondary piping • Place pumps at beginnings of zones . Placing them at the ends of zones could result in heating idle zones . • Siz e primary circuit manif o[...]

38 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. This drawing is conc eptual only . It shows representativ e piping components and la you t. W eil-McLain does not r epresent that this dra wing meets an y particular mechanical or building codes. The instal ler is responsible for inclusion of al l required sa[...]

P ar t Number PLUS-E017-A/1206 39 Manual • Installation • Start-Up • Usage • Maintenance • Parts 1. This drawing is conc eptual only . It shows representativ e piping components and la you t. W eil-McLain does not r epresent that this dra wing meets an y particular mechanical or building codes. The instal ler is responsible for inclusion [...]

40 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Figure 24 Dedicated single boiler with single water heater In residential application ( t y p i c a l l y G O L D P l u s 3 0 / 4 0 / 6 0 / 8 0 or Plus 40/60/80) . • Loc at e flo w /c hec k v a lv e as clos e as possib le to water heater boiler side connectio[...]

P ar t Number PLUS-E017-A/1206 41 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 25 Dedicated single boiler with single water heater In commercial application (typically PLUS 100/110/119). • Loc at e flo w /c hec k v a lv e as clos e as possib le to water heater boiler side connections — to reduce heat loss bet[...]

42 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Figure 26 Multiple water heaters — domestic water piping 1. The drawings on this page are conceptual only . They show representativ e piping components and la y out . W ei l-M cLain does not r epr es en t that thes e dra win gs mee t an y pa rticu lar mech ani[...]

P ar t Number PLUS-E017-A/1206 43 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 28 Multiple water heaters and dedicated multiple boiler s — boiler water piping (see legend and details in Figure 26, page 42) 1. This drawing is co nceptua l only . It shows repr esentati ve pip ing componen ts and la you t. W eil-Mc[...]

44 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Installation and start-up of water heaters connected to steam boilers See Figure 29, page 45, for suggested piping schematic. Pipe the domes tic wate r co nne ctio ns t o the wate r hea te r per Section A of this manual. • Boiler connec tions for the water hea[...]

P ar t Number PLUS-E017-A/1206 45 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 29 Steam boiler application Domestic water heating using water pumped from steam boiler • Locate flow/check v alv e as close as possible to w ater heater boiler side connections — to reduce heat loss between cycles. 1. These drawin[...]

46 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 w irinG requirements .............................................................................................. 47 Wiring requirements — Circulators ........................................................................... 47 Wiring requirements — Zone[...]

P ar t Number PLUS-E017-A/1206 47 Manual • Installation • Start-Up • Usage • Maintenance • Parts Electrical sho ck hazard. Can cause severe personal injury , death or substantial property damage. Disconnect powe r before installing and/or servicing . 1. All wir ing must be a minimum of 18 gauge and installe d in acc ordance with: • U.S.[...]

48 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusion of all required [...]

P ar t Number PLUS-E017-A/1206 49 Manual • Installation • Start-Up • Usage • Maintenance • Parts 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusi[...]

50 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusion of all required [...]

P ar t Number PLUS-E017-A/1206 51 Manual • Installation • Start-Up • Usage • Maintenance • Parts 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusi[...]

52 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 Figure 34 T ypical wiring: • Zoning with Weil-McLain zone valve contr oller (WMZV -4 shown) • Domestic priority optional (controller s witch) • Also refer to W eil-McLain Boiler Zone Wiring Guide f or fur ther details. • Refer to Wiring requirement s on [...]

P ar t Number PLUS-E017-A/1206 53 Manual • Installation • Start-Up • Usage • Maintenance • Parts 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusi[...]

54 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusion of all required [...]

P ar t Number PLUS-E017-A/1206 55 Manual • Installation • Start-Up • Usage • Maintenance • Parts 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusi[...]

56 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusion of all required [...]

P ar t Number PLUS-E017-A/1206 57 Manual • Installation • Start-Up • Usage • Maintenance • Parts Figure 39 T ypical wiring: • Zoning with zone valves • With domestic priority • PLUS 100/110/119 only • Also refer to W eil-McLain Boiler Zone Wiring Guide f or fur ther details. • Refer to Wiring requirement s on page 47. System pip[...]

58 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusion of all required [...]

P ar t Number PLUS-E017-A/1206 59 Manual • Installation • Start-Up • Usage • Maintenance • Parts 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusi[...]

60 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 1. These drawings are conceptual only . They show represe ntative piping co mponents and lay out. W eil-M cLain does not rep resent that the dra wing s meet any par ticular mechanical or building codes. The installer is responsible for inclusion of all required [...]

P ar t Number PLUS-E017-A/1206 61 Manual • Installation • Start-Up • Usage • Maintenance • Parts A. GOLD Plus 30, 40, 60 or 80 Plus 40, 60 or 80 ..................................................................................................................................... 50 B. PLUS 100, 110 or 119 ..................................[...]

62 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 GOLD Plus 30/40/60/80 or PLUS 40/60/80 Series 3 E Replacement parts continued[...]

P ar t Number PLUS-E017-A/1206 63 Manual • Installation • Start-Up • Usage • Maintenance • Parts Replacement par ts — GOLD Plus 30/40/60/80, Ultra Plus 40/60/80, Series 3 Item Description Size Manufacturer W eil-McLain Part Number 1 Thermostat Kit with Knob - No Cov er Plate W eil-McLain 633-900-130 not shown Drain V alve K it W eil-McL[...]

64 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 PLUS 100/110/119 Series 3 E Replacement parts continued[...]

P ar t Number PLUS-E017-A/1206 65 Manual • Installation • Start-Up • Usage • Maintenance • Parts Replacement par ts — PLUS 100/110 /119 Series 3 Item Description Size Manufacturer W eil-McLain P art Number 1 Ther mostat Kit with Knob - No Co ver Pla te W eil-McLain 6 35-100-010 2 PLUS100/110/119 Dip T ube Kit 1½" W eil-McLain 6 33[...]

66 P ar t Number PLUS-E017-A/1206 PLUS LINE Indir ect-Fired W ater Heaters – Series 3 W ater heater dimensions Dimensions — PLUS-Line indirect water heaters, Series 3 PLUS-Line Indirect-Fired W ater Heaters — Series 3 W ater Heater Model Storage Heati ng surface Head loss on Boiler- side Dimension s Ship. weight (approx.) DHW side Boiler side[...]

P ar t Number PLUS-E017-A/1206 67 Manual • Installation • Start-Up • Usage • Maintenance • Parts W ater heater performance ratings Boiler DOE Heating Capacity MBH First Hour Rating Capac ity (GPH) — Boiler W ater Supply at 200°F / Domestic W ater from 50°F to 115°F GOLD Plus 30 Boiler W ater GPM Minimum GOLD/ Ultra Plus 40 Boiler W a[...]

68 P ar t Number PLUS-E017-A/1206 Residenti al & Comme rci al Cast Ir on Boilers  R e si d ential W ater W a rranty — Lim ite d Life tim e  R e si d ential Steam W arranty — Li m ite d 10 Y e ar  Com m er ci al W arranty — Li m ite d 10 Y ear First Ye a r — (A ll Re si d ential & C om m er cia l Ca st I ron Boile rs) W ei l[...]