Indirect Fired Water Heater Manual 1

PLUS Line
Indirect-Fired Water Heaters

Series 3
Manual • Installation • Maintenance

• Startup • Parts
PLUS 100/110/119
GOLD Plus 30/40/60/80
Plus 40/60/80
This manual must only be used by a qualified heating installer/service technician. Before installing, read all instructions,
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.
Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Read this page first

Hazard 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
definitions 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.
Hot Water Can Scald!

• Water heated to temperature for clothes washing, dish washing and
other sanitizing needs can scald and cause permanent injury.
• Children, elderly, and infirm or physically handicapped persons are
more likely to be permanently injured by hot water. Never leave them
unattended in bathtub or shower. Never allow small children to use
a hot water tap or draw their own bath.
• If anyone using hot water in the building fits the above description,
or if state laws or local codes require certain water temperatures
at hot water taps, you must take special precautions:
• Use lowest possible temperature setting.
• Install some type of tempering device, such as an automatic
mixing valve, at hot water tap or water heater. Automatic
mixing valve must be selected and installed according to valve
manufacturer’s recommendations and instructions.
• Water passing out of drain valves may be extremely hot. To avoid
injury:
• Make sure all connections are tight.
• Direct water flow away from any person.
Protection Must Be Taken Against Excessive Temperature and Pressure!
— Installation of a Temperature & Pressure (T&P) relief valve is
required.

Manual • Installation • Start-Up • Usage • Maintenance • Parts
Contents
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 guidelines for domestic water connections to the water
heater. Section E lists replacement parts. Section F includes water heater dimen-
sions and ratings.
Section B provides boiler-side piping, wiring and start-up information for instal-
lations with Gas-fired boilers only. Notice that ALL Gas-fired boiler
installations require primary/secondary piping, as shown in Part B.
Sections C and D provide boiler-side piping and wiring information for installa-
tions with all boilers except Gas.
A. General installation (all water heaters)........................... 6

A1. Pre-installation
Codes............................................................................................................................. 6
Location......................................................................................................................... 6
Recommended clearances............................................................................................ 6
Operating restrictions.................................................................................................... 7
Code restrictions........................................................................................................... 7
A2. Water heater piping

Temperature & pressure relief valve............................................................................ 8
Air vent........................................................................................................................... 8
Piping drawings and drain valve information......................................................... 9-12
Thermal expansion...................................................................................................... 13
Water hammer............................................................................................................. 13
General piping information......................................................................................... 13
Domestic water piping................................................................................................ 14
Boiler water.................................................................................................................. 14
A3. Water heater wiring

Water heater thermostat connection.......................................................................... 15
A4. Water heater start-up

Filling the inner (domestic water) tank....................................................................... 16
Filling the outer (boiler water) tank............................................................................. 16
Start-up checklist......................................................................................................... 17
A5. Adjusting water heater temperature

Safety warning and General notes............................................................................. 18
Setting the thermostat — GOLD Plus 30/40/60/80 or Plus 40/60/80................ 19
Setting the thermostat — PLUS 100/110/119............................................................. 19
A6. Water heater maintenance

Maintenance schedule — Annual service by qualified technician............................ 20
Maintenance schedule — Homeowner’s monthly maintenance.............................. 20
Filling............................................................................................................................ 21
Draining........................................................................................................................ 21
Draining inner (domestic water) tank......................................................................... 21
Draining outer (boiler water) tank............................................................................... 21
A7. Recirculation and heat tracing

Maintaining domestic water temperature in the supply piping................................ 22
Time delay at fixtures.................................................................................................. 22
(continued on next page)
Contents continued
Balancing..................................................................................................................... 22
Components required................................................................................................. 22
Connecting to the water heater.................................................................................. 22
B. gas-fired boiler applications............................................... 24
B1. Install system water piping (space heating)

System water piping methods.................................................................................... 25
Boiler circulator........................................................................................................... 25
Sizing space heating system piping........................................................................... 25
Zoning with zone valves............................................................................................. 26
Zoning with circulators................................................................................................ 27
B2. Install boiler-to-water heater piping

Combined space heating/water heating applications................................................ 28
Dedicated water heating-only applications................................................................ 28
B3. Field wiring — Gas-fired boilers only

Installation must comply with:................................................................................... 30
Line voltage connections............................................................................................ 30
Wiring boiler circulator................................................................................................ 30
Wiring water heater circulator.................................................................................... 30
Wiring a system circulator.......................................................................................... 31
Routing line voltage wiring......................................................................................... 31
Low voltage connections............................................................................................ 31
Room thermostat (space heating).............................................................................. 31
Outdoor temperature sensor...................................................................................... 31
Water heater thermostat............................................................................................. 31
Additional limits........................................................................................................... 31
B4. Start-up — Gas-fired boilers only

Follow boiler manual................................................................................................... 33
Set space heating operation....................................................................................... 33
Water heater operation............................................................................................... 33
Water heater operation setup..................................................................................... 33
Verify space heating operation................................................................................... 33
Verify water heater operation..................................................................................... 34
Operating information................................................................................................. 34
Replace boiler jacket front door.................................................................................. 34
C. Boiler piping (except gas). ..................................................... 35
Zoning with pumps

GOLD Plus 30/40/60/80 or Plus 40/60/80
Two-pipe system piping — Figure 20........................................................................ 36
Primary/secondary piping — Figure 21...................................................................... 37
PLUS 100/110/119
Zoning with zone valves

Figure 23 (All water heater models)........................................................................... 39
Dedicated boiler applications

GOLD Plus 30/40/60/80 or Plus 40/60/80
Figure 24...................................................................................................................... 40
(continued on next page)
Contents continued
PLUS 100/110/119
Figure 25...................................................................................................................... 41
Multiple water heater applications

Multiple water heaters – water heater piping — Figures 26/27................................. 42
Boiler water piping for multiple water heaters — Figure 28...................................... 43
Steam boiler applications

Connecting water heater to steam boiler................................................................... 44
Installation and start-up of water heaters connected to steam boilers..................... 44
Steam boiler application piping and wiring (Figure 29)............................................. 45
D. Boiler-side wiring & controls (except gas)..... 46
Wiring requirements................................................................................................. 47
Wiring requirements — Circulators............................................................................ 47
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 • Domestic priority with priority relay (Figure 32)............... 50
• Using pump relays • No domestic priority (Figure 33)....................................... 51
• Pump relays • Priority with 3-way valve & priority relay (Figure 42).................. 60
Zoning with zone valves:

Zoning with Weil-McLain zone valve controller (WMZV)
• Domestic priority optional (controller switch) (Figure 34)...................................... 52
Zoning with 4-wire zone valves

• No domestic priority (Figure 35).............................................................................. 53
• With or without domestic priority • Models 30/40/60/80 (Figure 37)................. 55
• With domestic priority • PLUS 100/110/119 (Figure 39)..................................... 57
• With priority using 2-way priority valve • PLUS 100/110/119 (Figure 40).......... 58

• No domestic priority (Figure 36).............................................................................. 54
• With or without domestic priority • Models 30/40/60/80 (Figure 38)................. 56
• With domestic priority • PLUS 100/110/119 (Figure 39)..................................... 57
• With domestic priority using 2-way priority valve (Figure 41)............................... 59
E. Replacement parts......................................................................................... 61
GOLD Plus 30/40/60/80 or PLUS 40/60/80................................................... 62-63
PLUS 100/110/119.................................................................................................. 64-65
F. Water heater dimensions & performance ratings

Dimensions.................................................................................................................. 66
Performance ratings.................................................................................................... 67
Warranty...................................................................................................................... 68

A1 Pre-installation
Codes Installation must conform with instructions in this manual and, where applicable:
• local, state, provincial, and national codes, laws, regulations and ordinances.
• in Canada — B149.1 or B149.2 Installation Code.
PLUS water heaters are exempt from ASME Section VIII, Division 1 Code construction per
Interpretation VIII-1-86-136. Check with local codes for applicability.
Where recommendations in this manual differ from local or national codes, local or national
codes take precedence.
Location 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.
Recommended Installation location must provide adequate clearances for servicing and proper operation of
clearances the water heater.
GOLD Plus 30/40/60/80 or Plus 40/60/80 (see Figure 1)
• Zero clearance is permissible to either side of water heater, but Instruction label or other
labels may be hidden.
• Top (vertical) clearance is 12” minimum.
• Refer to boiler manual for boiler clearances.
PLUS 100/110/119 (see Figure 1)
• Zero clearance is permissible to either side of the water heater, but Instruction label or
other labels may be hidden.
• Top (vertical) clearance is 12” minimum.
• Refer to boiler manual for boiler clearances.
Figure 1
Clearance recommendations

A1 Pre-installation continued
Operating • Maximum domestic hot water temperature (Use only for special high-temperature
operational requirements):
restrictions • 160°F for GOLD Plus 30/40/60/80 or Plus 40/60/80.
• 190°F for PLUS 100/110/119.
• Maximum boiler water temperature — 210°F.
• Maximum working pressure for inner (domestic water) tank — 150 psig.
• Maximum working pressure for outer (boiler water) tank — 45 psig.
• pH and chloride limits for water heaters are:
• chloride — less than 80 mg/l.
• pH — above 6 and less than 8.
Code restrictions 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
of 1, as listed in Clinical Toxicology of Commercial Products, and
• boiler water pressure is limited to maximum 30 psig by approved relief valve.
Uniform Plumbing Code

Single-wall heat exchangers are permitted if they satisfy all of the following requirements —
1. The heat transfer medium is potable water or contains only substances which are recognized
as safe by the U. S. Food and Drug Administration.
2. The pressure of the heat transfer medium is maintained less than the normal minimum
operating pressure of the potable water system.
Exception: Steam complying with #1, above.
3. The equipment is permanently labeled to indicate that only additives recognized as safe
by the FDA shall be used in the heat transfer medium.
Other heat exchanger designs may be permitted where approved by the Administrative
Authority.

A2 Water heater piping

Temperature & To reduce risk of excessive pressures and temperatures in water heater,
pressure (T & P) install temperature and pressure protective equipment required by local
codes, but no less than a combination temperature and pressure relief
relief valve 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 30/40/60/80 or Plus 40/60/80: 3/4” NPT with an AGA Rating of
100,000 BTU/hr, with a long element. Set to relieve at 150 psi. (Watts model 100XL-8
relief valve or equivalent.)
• PLUS 100/110/119: 3/4” NPT with an AGA Rating of 200,000 BTU/hr, with a long
element. Set to relieve at 150 psi. (Watts model 40XL-8 relief valve or equivalent.)
GOLD Plus, Plus and PLUS water heaters are exempt from ASME Section VIII per
Interpretation VIII-1-86-136. Consult local codes for applicability.
2. Installing T&P relief valve –
GOLD Plus 30/40/60/80 or Plus 40/60/80 (Page 9)
• Install T&P relief valve either:
a. in tapping marked AUX.
b. in run (straight through leg) of tee located at domestic hot water outlet of water
heater. (Required for the Commonwealth of Massachusetts.) Use a long element
T&P relief valve.
PLUS 100/110/119 (Page 11)
• Install T&P relief valve either:
a. in tapping marked AUX.
b. in run (straight through leg) of tee located at domestic hot water outlet of water
heater. (Required for the Commonwealth of Massachusetts.) Use a long element
T&P relief valve.
3. T&P relief valve discharge piping must be:
• made of material serviceable for temperatures of 250°F or greater.
• directed so that hot water flows away from all persons.
• directed to a suitable place for disposal.
• installed so as to allow complete draining of the T&P relief valve and discharge line.
T&P relief valve discharge piping must not be:
• excessively long. Using more than 2 elbows or 15 feet of piping can reduce discharge
capacity.
• directly connected to a drain. Terminate discharge piping within 6” from floor. Refer
to local codes.
• plugged, reduced or restricted.
Do not install any valve between T&P relief valve and tank connection,
or on T&P relief valve discharge piping. Do not plug T&P relief valve or
discharge piping. Improper placement and piping of T&P relief valve can
cause severe personal injury, death or substantial property damage.
Air vent The boiler-side piping must be equipped with a diaphragm- or bladder-
type expansion tank, NOT a closed-type expansion tank.
1. Remove plastic shipping cap from 1/2” NPT pipe fitting on top of water heater.
2. Install automatic air vent provided with water heater, using suitable pipe dope or tape.
3. Unscrew vent cap on air vent one full turn. Leave cap unscrewed one turn for normal
venting.

A2 Water heater piping continued
Figure 2
Piping — OPTION 1
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 13. Failure to comply
could result in severe personal injury,
death or substantial property damage.
When the water supply pressure is higher than 70 psig, install a pressure-reducing valve on the cold water supply
line to prevent leakage from the T & P relief valve.
Drain valve Apply the following and Figure 2 to water heaters other than those installed in Massachusetts.
GOLD Plus 30/40/60/80 For Commonwealth of Massachusetts installations, see Option 2, Figure 3, page 9.
Option 1 1. Install the ¾” NPT brass tee (supplied with water heater) in the domestic water inlet piping
using suitable pipe dope or tape, located as shown in Figure 2.
2. Pipe the drain valve off of the brass tee as shown in Figure 2, using suitable pipe dope or
tape.
3. For jurisdictions requiring a vacuum breaker, use the piping shown in Figure 3, page 9,
(Option 2).
Figure 3
Piping — OPTION 2
Models 30/40/60/80 or
Plus 40/60/80
(Required for Commonwealth of
Massachusetts)
the DHW piping. See Thermal expan-
sion WARNING on page 13. Failure to
comply could result in severe personal
injury, death or substantial property
damage.
Drain valve Apply the following and Figure 3 to water heaters installed in Massachusetts. The drain valve
is mounted in the AUX tapping on top of the water heater.
GOLD Plus 30/40/60/80 1. Insert a close nipple and then an open-ended “draining” dip tube into the AUX tapping
or Plus 40/60/80 on top of the heater.
Option 2 2. Connect a ¾” NPT elbow to the AUX tapping, using suitable pipe dope or tape.
3. Pipe the drain valve (supplied with water heater) to the elbow, using suitable pipe dope or
tape, as shown in Figure 3.
4. Pipe the T & P relief valve in the run of the ¾” NPT brass tee (supplied with heater), located
in the domestic water outlet piping as shown in Figure 3.
10 Part Number PLUS-E017-A/1206

Figure 4
Piping — OPTION 1
PLUS 100/110/119
(See Figure 5, page 12, for OPTION 2,
required for Massachusetts)

damage.
Drain valve Apply the following and Figure 4 to water heaters other than those installed in Massachusetts.
For Commonwealth of Massachusetts installations, see Option 2, Figure 5, page 11.
PLUS 100/110/119 1. Install a brass tee in the domestic water inlet piping using suitable pipe dope or tape, located
Option 1 as shown in Figure 4.
2. Pipe the drain valve off of the brass tee as shown in Figure 4, using suitable pipe dope or tape.
3. For jurisdictions requiring a vacuum breaker, use the piping shown in Figure 5, page 11
(Option 2).
4. Obtain brass tee and drain valve from local supplier.
Part Number PLUS-E017-A/1206 11

Figure 5
Piping — OPTION 2
PLUS 100/110/119
(Required for Commonwealth of
Massachusetts)

damage.
Drain valve Apply the following and Figure 5 to water heaters installed in Massachusetts. The drain valve
is mounted in the AUX tapping on top of the water heater.
PLUS 100/110/119 1. Insert an open-ended “draining” dip tube into the AUX tapping on top of the heater.
Option 2 2. Connect a elbow to the AUX tapping, using suitable pipe dope or tape.
3. Pipe the drain valve to the elbow, using suitable pipe dope or tape, as shown in Figure 5.
4. Pipe the T & P relief valve in the run of the brass tee, located in the domestic water outlet
piping as shown in Figure 5.
5. Obtain brass tee and drain valve from local supplier.

Thermal expansion 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.
Water hammer 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.
General piping • For domestic water piping, see pages 8 through 12.
information • See pages 22–23, for domestic water recirculation piping.
• See Table 1 for piping connections:
• All plumbing must meet or exceed all local, state and national plumbing codes.
• Use pipe dope or tape suitable for potable water.
• Use isolation valves to isolate system components.
• See Section B for Gas boiler and system piping or Sections C boiler and system piping
with other boilers.
Table 1 Water Connections Recommended Recirculation Dip Tube

Heater Piping Between
Domestic Boiler Water Length Diameter
Piping (Inches NPT) Model Water Heater
Water Supply/ (inches) (inches)
and Boiler
Inlet/Outlet Return
30 ¾ 1 1 34 ¾
40 ¾ 1 1 42 ¾
60 ¾ 1¼ 1¼ 52 ¾
80 ¾ 1¼ 1½ 61 ¾
100 1½ 1½ 1½ 25 1½
110 1½ 1½ 1½ 32 1½
119 1½ 2 2 32 1½
If domestic water-side pressure exceeds 70 psig, install a pressure

reducing valve to prevent pressure spikes. Higher pressures can cause the
heater pressure/temperature valve to lift or weep.

Domestic water • 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.
piping • 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 230°F, which can be damaged by heat from soldering.
• When the supply pressure is higher than 70 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,
Boiler water • 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.
Inhibited propylene glycol is recommended.
Do not use automotive, ethylene glycol or petroleum-based antifreeze. Do

not use any undiluted antifreeze. This can cause severe personal injury,

A3 Water heater wiring

Water heater PLUS-Line indirect water heaters utilize a snap-set connector for easy wiring between water
thermostat heater thermostat and boiler controls (also see Section B or D). See Figure 6, below.
connection
Figure 6
Thermostat connection
Terminal 1 of the snap-set is the normally-open contact; terminal 2 is the

normally-closed contact; terminal C is common.

A4 Water heater start-up

Filling the inner • Inner tank must be completely filled and pressurized before pres-
(domestic water) surizing outer tank.
• Never use water heater unless inner and outer tanks are completely filled
tank with water.
1. Close domestic water drain valve.
2. Open domestic water isolation valves for water heater.
3. 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.
4. Close hot water faucet.
Filling the outer • Inner tank must be completely filled and pressurized before pres-
surizing outer tank.
(boiler water) tank • Never use water heater unless inner and outer tanks are completely filled
with water.
1. Close boiler water drain valve at boiler water outlet of water heater.
2. Open water heater’s boiler water isolation valves.
3. Allow air to escape from outer (boiler water) tank by opening cap “A” (see Figure 7) on
automatic air vent, located on top of water heater. See the NOTICE below.
Figure 7 A
Open cap on air vent to allow air
to escape from outer tank B
6406-6
For proper operation of the water heater, always leave vent cap unscrewed
one full turn.
The boiler-side piping must be equipped with a diaphragm- or bladder-
type expansion tank, NOT a closed-type expansion tank.
4. Follow instructions furnished with boiler to fill with water.
5. When tank is full, air will stop escaping, and air vent will close. If air vent does not seat
properly (i.e., water leaks out), remove cap “A”. Briefly push in valve “B” (see above) and
release it to clean valve seat. Screw cap “A” on completely, then unscrew one turn.
6. If antifreeze is used in boiler water, check concentration. Boiler water (including addi-
tives) must be practically non-toxic, having a toxicity rating of Class 1, as listed in Clinical
Toxicology of Commercial Products. Inhibited propylene glycol is recommended. Follow
antifreeze manufacturer’s instructions.
death or substantial property damage if ignored.

A4 Water heater start-up continued
Start-up checklist ❏ 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

A5 Adjusting water heater temperature
Hot Water Can Scald!

• Water temperature over 125°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 130°F or less. Setting thermostat higher than
130°F setting will increase risk of scald injury and
can cause severe personal injury or death.
• Water heated to a temperature suitable for
clothes washing, dish washing and other sani-
tizing needs will scald and cause permanent
injury.
• Children and elderly, infirm, or physically handi-
capped persons are more likely to be injured by
hot water. Never leave them unattended in or near
a bathtub, shower or sink. Never allow small chil-
dren to use a hot water faucet or draw their own
bath. If anyone using hot water in the building
fits this description, or if state laws or local codes
require certain water temperatures at hot water
faucets, take special precautions:
• Install an automatic mixing valve at water
heater or at each hot water faucet, bath, and
shower outlet. Selection and installation
must comply with valve manufacturer’s
recommendations and instructions.
• Use the lowest practical temperature setting.
• Check water temperature after any
adjustment. You must follow “Setting the
Thermostat” on page 19.
General notes • Household water usage patterns will affect water

temperature at any faucet or shower. Occasionally
check temperature at each point of use, then adjust
thermostat accordingly. Always recheck tempera-
ture after adjusting thermostat.
• When hot water is used in repeated small quantities,
a “stacking” effect can develop in hot water tank.
The upper layer of water in tank can be much hotter
than lower layers.
• Lowering the thermostat setting or installing
automatic mixing valves as indicated in these in-
structions will reduce water temperature levels.
Consult your installer or service technician.

A5 Adjusting water heater temperature continued
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 Setting the thermostat

GOLD Plus 30/40/60/80 PLUS 100/110/119
or Plus 40/60/80
Factory Setting
Water heater thermostat is factory set to its lowest tem- Water heater thermostat is factory set to its lowest tem-
perature. The arrowhead indicator on the label is the perature. The white factory setting mark on the label is the
preferred starting point for setting temperature. This may preferred starting point for setting temperature. This may
or may not be suitable for your needs. or may not be suitable for your needs.
Turn thermostat knob clockwise  to increase water Turn thermostat knob clockwise  to increase water
temperature. temperature.
Turn thermostat knob counter-clockwise  to reduce Turn thermostat knob counter-clockwise  to reduce
water temperature. water temperature.
When decreasing temperature setting, the stored hot water When decreasing temperature setting, the stored hot water
must be used before checking temperature at faucet. must be used before checking temperature at faucet.
Check water temperature at a hot water faucet immediately Check water temperature at a hot water faucet immediately
after first heating cycle. Further temperature adjustment after first heating cycle. Further temperature adjustment
may be necessary as water heating system is used. Recheck may be necessary as water heating system is used. Recheck
water temperature at faucet after adjustment. water temperature at faucet after adjustment.
When adjusting thermostat, be sure boiler limit control is When adjusting thermostat, be sure boiler limit control is
set a minimum 20°F higher. set a minimum 20°F higher.
At no time should boiler limit control be At no time should boiler limit control be
set above 210°F. This can cause severe set above 210°F. This can cause severe
personal injury, death or substantial personal injury, death or substantial
property damage if ignored. property damage if ignored.

A6 Water heater maintenance

Maintenance Annual service by qualified service technician to include:
schedule – annual • Any procedures required by local codes.
service technician • 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
cause severe personal injury or
substantial property damage.
6406-10
• 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
water, close cold water inlet to water heater immediately. Follow draining instructions,
and replace T&P relief valve. If T&P relief valve weeps periodically, it may be due to
thermal expansion (see “Thermal Expansion”, page 13). Do not plug T&P relief valve
or discharge piping.
Plugging T&P relief valve or discharge piping can cause excessive pres-
sure in water heater, resulting in severe personal injury, death or substantial
property damage.
• Follow instructions on circulator to oil it, if oil-lubricated.
• Check valves, pipes and fittings for leaks.
• Check function of field-installed controls and valves (see control manufacturer’s instruc-
tions).
• Review homeowner’s maintenance responsibilities and their frequencies, including any
not listed in the following paragraphs.
Maintenance Homeowner monthly maintenance to include:

schedule – monthly • Check air vent operation:
homeowner • Automatic air vent — remove cap (see Figure 8). Briefly push in valve and release it to
clean valve seat. Screw cap on completely, then unscrew one turn. If air vent does not
operate, call qualified service technician.
A
Figure 8
B
Remove air vent cap to check
operation
6406-6
• Visually check valves, pipes and fittings for leaks. Call qualified service technician to repair
leaks.

A6 Water heater maintenance continued
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 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.
If boiler water does not contain sufficient antifreeze, then the boiler water and the domestic
water must be drained.
Close boiler water isolation valves and relieve pressure to below 15 psi in
outer tank before draining inner tank to prevent damage to inner tank.
If antifreeze is used in boiler water, check concentration. Boiler water (including additives)
must be practically non-toxic, having toxicity rating or class of 1, as listed in Clinical Toxicol-
ogy of Commercial Products. Inhibited propylene glycol is recommended. Follow antifreeze
manufacturer’s instructions.

death or substantial property damage if ignored.
Water from opened drain valves, unions and other connections may be
extremely hot. To avoid severe personal injury, death or substantial property
damage:
• Tighten all drain hose connections.
• Direct hot water away from all persons.
Draining inner See piping drawings, pages 9–12.

(domestic water) 1. Disconnect power supply to water heater.
• If outer (boiler water) tank pressure is greater than 15 psig, relieve boiler pressure to
tank less than 15 psig, and close isolation valves before proceeding.
2. Close cold water supply isolation valve.
3. Remove cap and connect a hose to domestic water drain valve. Hose should extend to drain
at floor level to allow siphoning of domestic water tank.
4. Open union on domestic water outlet or hot water faucet at highest point above heater.
5. Open domestic water drain valve to start siphoning.
6. When draining is complete, close union or hot water faucet and domestic water drain
valve.
Draining outer See piping drawings, pages 9–12.

(boiler water) tank 1. Disconnect power supply to water heater.
2. Close boiler water isolation valves between water heater and boiler.
3. Connect hose to boiler water drain valve at water heater. Open and drain water to a safe
place.
4. To speed draining, loosen air vent on top of tank.
5. When draining is complete, close drain valve and retighten air vent.

A7 Recirculation and heat tracing

Maintaining domestic water temperature in the These branches must be balanced to prevent pipe ero-
supply piping sion and unacceptable time delays at some fixtures.
Two options are available to maintain supply temperature available at or Balancing options include circuit setters, memory stop
near the fixtures on storage water heating systems: valves or factory preset devices (with flow metering
provision in the piping).
· Recirculation
Recirculation is used to reduce wait time for water use, to minimize Components required
hot water and energy waste caused during the waiting period, and to
prevent degradation of the system supply water temperature. ASPE For residential applications, consult pump manufactur-
recommends recirculation when the distance from the water heater er’s data for pump selection and additional components
to the furthest fixture exceeds 100 feet or the time lag for hot water to required.
reach a fixture(s) exceeds 30 seconds. Consult local codes and American
Society of Plumbing Engineers (ASPE) Domestic Water Heating Design On most commercial systems, install the devices shown
Manual, 1998, for further information. in Figure 9, page 23, and any other devices or piping
methods required by local codes. The check valves
· Self-regulating heat tracing are required to prevent fixtures from taking hot water
Self-regulating heat tracing may be a better alternative than recircula- through the return lines. Shutoff valves are needed to
tion for residential and small commercial applications. Self-regulating allow cleaning and replacing balancing devices. Include
heat tracing uses electrical energy to maintain water temperature, but strainers to remove sediment which could damage the
it eliminates the need for return piping and components required in a pump and/or affect the flow balancing devices.
recirculation system.
Size the pump and piping based on the temperature
drop allowed between the water available at the water
Time delay at fixtures
heater and the water delivered at the fixture. The return
Table 2 is from the ASPE Domestic Water Heating Design Manual, 1998. It piping will almost always be smaller than the supply
shows the time required for usable hot water to arrive at a fixture based on piping, but should never be smaller than ½” to prevent
the fixture flow rate (available from industry and manufacturer’s data) and problems with the pump.
the length and diameter of the dead-end branch pipe supplying the fixture.
The time lag should generally not exceed 30 seconds. For residential and Make provision for removal of air in all return lines.
office applications, the owner may prefer a limit of 10 seconds. Where the returns cannot be vented by topmost fixtures
in the system, install automatic air venting at the top
You can use Table 2 as a guide to determining the location of circula-
tion return lines relative to fixtures. of the return piping.
Balancing Connecting to the water heater

When multiple branches are connected to the supply piping, each branch Install a recirculation dip tube in the AUX tapping on
must be connected to the recirculation system. At each of these connec- top of the water heater. This requires mounting the
tions to the return piping, install shutoff valves, a flow metering device, T&P relief valve as shown for Option 2 in the piping
check valve and a strainer as shown in Figure 9 on page 23. Check local diagrams, pages 10 and 12. See Figure 10, page 23, for
codes for specific installation requirements. the piping required to the water heater.
Table 2 Time in seconds required to get hot water at fixture (from ASPE)
Fixture flow rate (GPM) - 0.5 1.5 2.5 4.0
Time lag to obtain hot water at
Piping length (feet) - 10 25 10 25 10 25 10 25
fixture for branch lengths of 10
Copper pipe ½" 25 63 8 21 5 13 3 8
and 25 feet
(ASPE Domestic Water Heating Design Manual) ¾" 48 119 16 40 10 24 6 15
Steel pipe ½" 63 157 21 52 13 31 8 20
¾" 91 228 30 76 18 46 11 28
CPVC pipe ½" 64 159 21 53 13 62 8 20
¾" 95 238 32 79 19 48 12 30
NOTE: Select branch size and length for less than 31 seconds delay.

Figure 9
Recirculation components
Figure 10 Recirculation connection at water heater
Components
1 Circulator — Little flow is required to maintain a temperature in the piping. Size of • When temperature at aquastat #2 falls 10° below temperature to be maintained
circulator depends on minimum flow requirements of the tempering valve. Minimum — Circulator is on. There is flow through #6 equal to the minimum required by the
flow rates of the tempering valve must be maintained. mixing valve, flow through #3 and #4 equals the flow of the circulator. There is no flow
2 Aquastat — Used to control the on-off position of the circulator. Aquastat is set 5° to through #5.
10° lower than mixed water outlet of the mixing valve (#7). The circulator cannot run • Aquastat reaches temperature — Circulator is off. There is no flow through #3, #4, #5
continuously as bypass through the mixing valve will eventually allow the temperature or #6.
on the piping to climb to the water heater temperature during draw periods. Problems
3 – 6 Check valves — Assure the flow of water in one direction. Each check valve func- • Missing check valves #3 or #4 — Extreme pressure drop can cause reverse flow of
tions as follows: #3 and #4 prevent bypass in the event of pressure drop, #5 prevents water; hot to cold supply or cold to hot supply.
thermal siphoning of hot water to the cold water supply, #6 prevents flow of cold water • Missing check valve #5 — Hot water can migrate from the water heater back through
to the tempered water supply. A draw of tempered water will not result in flow of cold the cold water supply.
water into the return loop. • Missing check valve #6 — Cold water can be forced back through the tempered water
Operation supply when a fixture is opened.
• During period of normal use (fixtures on) — Circulator is off. There is no flow through • No aquastat #2 — Pump runs continuously. Small amount of water will pass through
#6, there is flow through #5 equal to the flow at the fixtures, there is flow through #3 mixing valve. Eventually all hot water is flowing through valve. Recirculated water
and/or #4 equal to flow at fixture. through cold port, hot water through hot port.
• When all fixtures are off — Circulator is off. There is no flow through #3, #4, #5 or #6. • Circulator too small — Mixing valve performance erratic.
Water temperature in piping is cooling.

B
gas
Gas-fired 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 D for other boiler applications.
B1. Install system water piping

System water piping methods.................................................................................... 25
Boiler circulator........................................................................................................... 25
Sizing space heating system piping........................................................................... 25
Zoning with zone valves............................................................................................. 26
Zoning with circulators................................................................................................ 27
B2. Install boiler-to-water heater piping

B3. Field wiring — Gas-fired boilers only

Installation must comply with:................................................................................... 30
Line voltage connections............................................................................................ 30
Wiring boiler circulator................................................................................................ 30
Wiring PLUS circulator................................................................................................ 30
Wiring a system circulator.......................................................................................... 31
Routing line voltage wiring......................................................................................... 31
Low voltage connections............................................................................................ 31
Room thermostat (space heating).............................................................................. 31
Outdoor temperature sensor...................................................................................... 31
PLUS water heater thermostat.................................................................................... 31
Additional limits........................................................................................................... 31
B4. Start-up — Gas-fired boilers only

Follow boiler manual................................................................................................... 33
Set space heating operation....................................................................................... 33
Water heater operation............................................................................................... 33
Water heater operation setup..................................................................................... 33
Verify space heating operation................................................................................... 33
Verify water heater operation..................................................................................... 34
Operating information................................................................................................. 34
Replace boiler jacket front door.................................................................................. 34

B1
gas
Install system water piping (space heating)
System water piping Figure 11 Expansion tank piping

methods
All piping methods shown in this manual
use primary/secondary connection to the
boiler loop. These designs ensure proper
flow through the Gas boiler, for
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 Gas boiler piping guides.
Wall-mounted boilers — Piping can exit

bottom of boiler enclosure. See separate
wall-mounting instructions for details.
Expansion tank and make-up

water
The boiler-side piping must be
1. Ensure expansion tank size will handle boiler and equipped with a diaphragm- or
system water volume and temperature. Allow 3 bladder-type expansion tank, NOT
gallons for the boiler and its piping. a closed-type expansion tank. This
is necessary to allow venting air
Undersized expansion tanks cause system from the top of the indirect water
water to be lost from relief valve and heater boiler-side.
make-up water to be added through fill
valve. Eventual boiler failure can result
due to excessive make-up water addi-
tion. Boiler circulator
2. Tank must be located as shown in this supplement, The boiler circulator is shipped loose. It must be located
or following recognized design methods. See tank in either the return or supply piping, as shown in the
manufacturer’s instructions for details. appropriate piping diagram in this supplement or the
Boiler Manual.
3. Connect the expansion tank to the air separator
only if the separator is on the suction side of the DO NOT use the boiler circulator in any
system circulator. Always install the system fill con- location other than those shown in this
nection at the same point as the expansion tank manual or the boiler manual. The boiler
connection to the system. circulator is selected to ensure adequate
flow through the boiler. Failure to
4. The piping drawings in this manual show only comply could result in unreliable per-
diaphragm expansion tanks. Use only bladder-type
or diaphragm-type tanks with PLUS indirect water formance and nuisance shutdowns from
heater applications. insufficient flow.
5. Refer to the Boiler Manual for other system

piping examples.
Sizing space heat system
Diaphragm (or bladder) expansion tank piping
1. Always install an automatic air vent on top of the air 1. See Figures 12 and 13, pages 26 and 27, or the
separator to remove residual air from the system. Gas Boiler Manual for recommended piping. In all
2. See Figure 11 for correct location of the expansion diagrams, the space heating system is isolated from
tank. the boiler loop by the primary/secondary connec-
tion.
DO NOT USE a closed-type expansion tank 2. Size the piping and components in the space heating

B1
gas
Install system water piping (space heating) (continued)
Zoning with zone valves Figure 12 Zone valve zoning plus optional water
1. Connect boiler to system as shown in Figure 12 heater piping
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.
The PhD Control Module turns off
space heating during water heater heat-
ing. The boiler circulator will turn off,
preventing hot water from circulating to
the system. The flow/check valve shown
on the boiler outlet piping prevents grav-
ity circulation in the boiler loop during
water heater heating.
3. Controlling the system circulator
a. To cycle the system circulator from the PhD
control module, add a circulator relay wired to the
boiler circulator terminals as shown on page 30.
NOTE 1: To ensure adequate flow rate through the

boiler, use the following pipe size on all
boiler loop piping (connecting boiler to and
from the primary/secondary connection,
item 21):
-80 or -105 – 1” or larger.
-155 or -230 – 1¼” or larger.
-310 – 1½” or larger.
Use at least the minimum piping size
above and pipe the boiler using only pri-
mary/secondary piping as shown. Failure
to follow these guidelines could result in
system problems.
Legend Figure 12
1 boiler 9 Air separator [with automatic air vent only on systems
2 PLUS-Line indirect water heater using diaphragm (or bladder) type expansion tank]
3 Boiler relief valve (see boiler manual for piping details) 10 Flow/check valves (with weighted seats to prevent gravity
circulation)
4 Boiler relief valve discharge piping (see boiler manual for
details) 11 Purge/drain valves
5 Water heater circulator (see page 7 for suggested 12 Boiler circulator

sizing) 13 Zone valves, typical
6 Isolation valves 20 Make-up water supply
7 System circulator 21 Primary/secondary connection
8 Diaphragm (or bladder) type expansion tank (see page 3
for piping of closed-type expansion tank, if used)

B1
gas
Install system water piping (space heating) (continued)
Zoning with circulators Figure 13 Circulator zoning plus optional water

1. Connect boiler to system as shown in Figure 13 heater piping
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.
3. Connect water heater (domestic hot water) pip-
ing to indirect storage water heater as shown in
Section A of this manual.
The PhD Control Module turns off
space heating during water heater heat-
ing. The boiler circulator will turn off,
preventing hot water from circulating to
the system. The flow/check valve shown
on the boiler outlet piping prevents grav-
ity circulation in the boiler loop during
water heater heating.
NOTE 1: To ensure adequate flow rate through the
boiler, use the following pipe size on all boiler
loop piping (connecting boiler to and from
the primary/secondary connection, item
21):
-80 or -105 – 1” or larger.
-155 or -230 – 1¼” or larger.
-310 – 1½” or larger.
Use at least the minimum piping size
above and pipe the boiler using only pri-
mary/secondary piping as shown. Failure
to follow these guidelines could result in
system problems.
Legend Figure 13
1 boiler 10 Flow/check valves (with weighted seats to prevent gravity
2 PLUS-Line indirect water heater circulation)
3 Boiler relief valve (see boiler manual for piping details) 11 Purge/drain valves
4 Boiler relief valve discharge piping (see boiler manual for 12 Boiler circulator
details) 14 Zone circulators, typical
5 Water heater circulator (see page 7 for suggested sizing) 20 Make-up water supply
6 Isolation valves 21 Primary/secondary connection
7 System circulator
8 Diaphragm (or bladder) type expansion tank (see page 3
for piping of closed-type expansion tank, if used)
9 Air separator [with automatic air vent only on systems using
diaphragm (or bladder) type expansion tank]

B2
gas
Install boiler-to-water heater piping

Combined space heating/water Dedicated water heating-only
heating applications applications
1. Figure 14 shows recommended piping between Gas 1. Figure 15 shows recommended piping between Gas
boiler and PLUS water heater. All show direct connection Boiler and PLUS water heater for dedicated water-heating
of the water heater piping to the boiler because the boiler only applications.
circulator shuts down during water heater operation. 2. Pipe sizing:
2. Table 3, page 29, uses the recommended flow rates for the Table 4, page 29, provides the recommended minimum pipe
PLUS water heater and minimum flow rates for the size for boiler-to-water heater piping.
Gas boiler to provide recommended water heater piping
and circulator sizing. If using another circulator, verify it is 3. Circulator:
at least equal to the Taco selection given in Table 3, page 29. Use the circulator recommended in Table 4, page 29. Install
For general information on head loss through boiler and the circulator as shown in Figure 15.
boiler-to-water heater piping, refer to the Gas Boiler 4. Procedure:
Manual.
3. Procedure: Step 1: Select Gas Boiler model and water heater
model in Table 4, page 29.
Step 1: Select Gas Boiler model and water heater model
in Table 3, page 29. Step 2: Read flow rate expected using the circulator speci-
Step 2: Read recommended minimum flow rate, GPM, in fied inthe last column.
table. Step 3: Size connecting piping as listed under “Boiler pip-
Step 3: Read across to find recommended minimum pipe size ing” in the table.
for boiler-to-water heater piping.
Step 4: Read across to find recommended Taco circulator model.
Use a circulator with a pump curve at least equal to the
Taco circulator shown. See Figure 16, page 29 for pump
Figure 15 Boiler-to-water heater piping —
curves of typical Taco circulators. Dedicated water-heating only application
Figure 14 Boiler-to-water heater piping — Combined

space heating/water heating application
3 Boiler relief valve (see Boiler Manual for piping details)

4 Relief valve discharge piping (see Boiler Manual for details)
3 Boiler relief valve (see Boiler Manual for piping details) 5 Water heater circulator — (see Table 4, page 29)
4 Relief valve discharge piping (see Boiler Manual for details) 8 Expansion tank (diaphragm or bladder type)
5 Water heater circulator — must be at least equal in capacity to circulator
6 Isolation valves
recommended in Table 3, page 29
6 Isolation valves 10 Flow/check valve (with weighted seat)
10 Flow/check valve (with weighted seat to prevent gravity circulation) 11 Purge/drain valve
11 Purge/drain valves 20 Fill line to fill valve (item 23)

The following ratings are for Ultra Gas boilers only, with supply water temperature at 190°F. gas
For boilers other than Ultra Gas, see page 67 for ratings.
Table 3 Combined space heating/water Table 4 Dedicated water-heating, using circulator

heating (see Notes) supplied with boiler (see Notes)
Boiler PLUS 1st Hour Boiler Head losses, Feet w.c. DHW Boiler PLUS 1st Hour Boiler Head losses, Feet w.c. Circ.
Model rating, GPH piping Pump Model rating, GPH piping
Rec. Rec.
115°F 140°F GPM Boiler Heater Piping TOTAL 115°F 140°F GPM Boiler Heater Piping TOTAL
size size
40 160 124 40 160 124
60 168 132 60 168 132
Ultra- 80 176 140 Ultra- 80 176 140

6.6 1" 5.8 1.0 2.4 9.2 007 6.6 1" 5.8 1.0 2.4 9.2 007
80 100 190 155 80 100 190 155
110 210 175 110 210 175
119 230 190 119 230 190
40 203 141 40 203 141
60 211 162 60 211 162
Ultra- 80 219 170 Ultra- 80 219 170

6.4 1" 5.9 1.0 2.3 9.3 007 6.4 1" 5.9 1.0 2.3 9.2 007
105 100 230 185 105 100 230 185
110 250 205 110 250 205
119 270 225 119 270 225
40 238 153 8.7 1" 5.7 1.0 3.9 10.6 40 250 160
0010
60 294 190 9.6 1¼" 7.1 1.0 2.3 10.5 60 295 220
Ultra- 80 302 230 Ultra- 80 305 230

12.1 1¼” 11.4 1.0 4.5 16.9 0014
155 100 315 245 155 100 315 245
10.8 1¼" 9.0 1.0 2.8 12.8 0012
110 335 265 110 335 265
119 355 285 119 355 285
40 248 160 40 240 170
12.0 1¼" 8.2 1.0 3.4 12.6 0012
60 330 196 60 335 220
Ultra- 80 411 305 Ultra- 80 430 325

13.5 1¼” 10.0 1.0 5.2 16.2 0014
230 100 440 335 230 100 440 335
13.5 1¼" 10.0 1.0 4.2 15.2 0014
110 460 355 110 460 355
119 480 375 119 480 375
40 254 164 15.0 1¼" 6.0 1.0 5.1 12.1 0012 40 240 170
60 351 208 18.6 1½" 8.5 1.0 3.3 12.8 0011 60 335 220
Ultra- 80 579 373 Ultra- 80 580 410

18.3 1½” 8.3 1.0 4.2 13.5 0014
310 100 440 335 310 100 590 435
22.0 1½" 11.2 1.0 4.5 16.6 0013
110 460 355 110 610 465
119 480 375 119 630 485
Notes Tables 3 and 4 Figure 16 Pump curves for Taco circulators
1. First hour ratings in Tables 3 and 4 are based

on:
• 115°F or 140°F domestic outlet water supply
temperature from water heater.
• 50°F domestic water inlet temperature.
• 190°F boiler water temperature leaving
Gas boiler.
• Circulator and pipe sizes as given in the
Tables.
2. If the net Btu/hr rating of the boiler is close to
the space heating load (for combined systems)
— or if there is an unusually large demand for
domestic water — increased boiler capacity
may be required.

B3
gas
Field wiring — Gas boilers only

ELECTRICAL SHOCK HAZARD Line voltage connections
— For your safety, turn off electrical
power supply at service entrance panel 1. Connect 120 VAC power wiring to line voltage
before making any electrical connections terminal strip in left compartment of electrical
to avoid possible electric shock hazard. entrance, as shown in Figure 17, item 1.
Failure to do so can cause severe personal 2. Provide and install a fused disconnect or service
injury or death. switch (15 amp. recommended) as required by the
code. (See Figure 17, item 2)
Wiring must be N.E.C. Class 1.
If original wiring as supplied with boiler

Wiring boiler circulator
must be replaced, use only type 105 °C 1. The Taco 0011 circulator supplied with the boiler is
wire or equivalent. wired one of two locations, depending on whether
system is combined space heating/water heating or
Boiler must be electrically grounded as dedicated water-heating only. Boiler circulator is
required by National Electrical Code shipped loose. Wire Boiler circulator to terminals
ANSI/NFPA 70 – latest edition. (refer to Figure 17):
a. Combined system: terminals 5, 6, and 7 (installed as
Figure 17, item 3).
b. Dedicated system: terminals 3, 4, and ground wire nut
Installation must comply with: (installed as Figure 17, item 5).
1. National Electrical Code and any other national,

state, provincial or local codes or regulations. Wiring water heater circulator
1. For combined systems, connect water heater circu-
2. In Canada, CSA C22.1 Canadian Electrical Code lator to line voltage terminal strip terminals 3 and
Part 1, and any local codes. 4 and ground wire nut. See Figure 17.
Figure 17 Line voltage field wiring connections (service switch provided by installer)

B3
gas
Field wiring — Gas boilers only (continued)

Wiring a system circulator 4. Install a summer/winter switch (Figure 19, item 7)
across terminals 1 and 2 to force fixed-temperature
1. For combined systems, to activate a system circu- operation during summer months. (When the
lator when the Boiler circulator operates, wire as switch is closed, boiler will attempt to maintain
shown at bottom of Figure 17, page 30. constant temperature.)
2. You must install a relay as shown. DO NOT wire in 5. Route sensor wires through the grommeted hole at
parallel with the Boiler circulator. See CAUTION in right of the electrical entrance (see Figure 18).
Figure 17.
Water heater thermostat

Routing line voltage wiring 1. Connect PLUS water heater aquastat terminals
1. Route line voltage connections to the jacket open- “C” and “1” to Gas boiler low voltage ter-
ings shown in Figure 18. minal strip between terminals 3 and 4 (Figure 9,
item 3).
Low voltage connections Additional limits

(Fig. 18)
1. Connect additional limit controls and interlocks
1. Connect low voltage wiring to low voltage termi- between the terminals shown in Figure 19.
nal strip (Figure 19, page 32, item 1) as shown in 2. Controls connected between terminals 6 and 7
Figure 19 and the boiler wiring diagram. (see Figure 19, item 4) will cause a soft lockout
2. Route all low voltage wires through grommeted (automatic reset). When limit(s) closes, boiler will
jacket opening to right of low voltage terminal strip, resume normal operation.
as shown in Figure 18. 3. Controls connected between terminals 6 and 8
(see Figure 19, item 5). will cause a hard lockout
(manual reset). The boiler will only restart after
Room thermostat (space heating) the Ultra display panel RESET switch is pressed.
1. For combined space heating/water heating systems, Figure 18 Routing field wiring
connect Figure 19, item 2, room thermostat or end
switch (isolated contact only) between terminals 5
and 6.
2. Install thermostat on inside wall away from influ-
ences of drafts, hot or cold water pipes, lighting
fixtures, television, sunrays, or fireplaces.
3. Thermostat anticipator (if applicable):
a. If connected directly to boiler, set for 0.1 amps.
b. If connected to relays or other devices, set to match
total electrical power requirements of connected
devices. See device manufacturers’ specifications and
thermostat instructions for details.
Outdoor temperature sensor

1. Outdoor reset operation applies only to combined
space heating/water heating systems.
2. Connect outdoor temperature sensor (Figure 19,
item 6) between terminals 1 and 2 to enable out-
door reset operation of the Gasboiler. If
fixed-temperature operation is required, do not
install outdoor sensor.
3. Mount sensor on exterior wall, shielded from di-
rect sunlight or flow of heat or cooling from other
sources.

B3
gas
Field wiring — Gas boilers only (continued)

Figure 19 Low voltage field wiring connections
Summer/winter switch (item 7) — 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.

B4
gas
Start-up — Gas boilers only

Follow boiler manual Water heater operation setup
1. Follow all procedures in the Gas boiler manual 1. Go to step 2 if the control is in Parameter mode
to start up and verify operation of the boiler. already. Press the “Mode” button until the display
shows “Para” (parameter mode).
2. Press the “Step” button until the display first digit
Set space heating operation shows “2.”
3. The last digit must show “1.” If any other number
Verify space heating mode displays, press the “+” button until “1” shows in the
1. Press the “Mode” button until the display shows right-hand digit. Press the “Store” button to save
“Para.” This is the parameter mode. this setting.
2. Press the “Step” button until the display first digit 4. The PhD control module turns on the PLUS
shows “3.” circulator when the indirect water heater operating
control closes. The control module shuts off the
3. The last digit must show “1.” If any other number boiler circulator (stops space heating) during calls
displays, press the “+” button until “1” shows in the for DHW heating.
right-hand digit. Press the “Store” button to save
this setting.
Set space heating target temperature Verify space heating operation

1. Press the control panel “Step” button until NOTE: “[ _ _ _ _ ]” in the following indicates the
the display first digit shows “4.” The right 3 digits characters that should show on the display panel.
show the outlet water temperature setting. “180” in the right 3 places means the display shows the
2. Press the “+” or “-” button to change the setting to measured boiler water temperature. The number shown
the desired outlet water temperature. (The factory will not necessarily be 180.
default setting is 190 °F.) 1. Turn down aquastat on PLUS tank. If necessary,
a. Outdoor sensor installed — Setting is the target turn off power and remove one of the PLUS aqua-
temperature for outdoor temperature at or below stat wires to ensure boiler will not receive a DHW
32 °F. At higher outside temperatures, the PhD heat call.
control module calculates the target temperature. (See
Control Supplement for detailed discussion of 2. Turn off power to boiler at service switch.
outdoor reset.) 3. Wait a few seconds, then turn on power to boiler.
When a summer/winter switch is used, closing the [A180] (self-check on power-up, for a few seconds)
switch will disable the boiler (space heating) circulator
[0180] (no call for heat)
during summer operation.
b. Outdoor sensor not installed — Setting is the target 4. Raise room thermostat to call for heat.
temperature at all times. [5180] (blower/circulator on) The blower and boiler circu-
3. Press the “Store” button to save the setting. lator energize and the control checks for air flow.
[1180] (prepurge) After a few seconds delay (control self-
check), blower speed will increase to ignition speed.
The blower will run in prepurge for 10 seconds.
Water heater operation [2180] (ignition) After prepurge, the control module
1. The PLUS water heater thermostat must be con- opens the gas valve and starts ignition spark.
nected to low voltage terminal strip terminals 3 a. If burner flame proves within 4.5 seconds, burner
and 4 as shown on page 10. continues to fire. Burner will fire at start-up
2. When the water heater thermostat calls for heat, rate — 50% of maximum input — for about 10
the module shuts down the boiler circulator, acti- seconds to allow flame to stabilize.
vates the water heater circulator and immediately b. If burner flame does not prove within 4.5 sec-
sets target outlet water temperature to 190°F. This
provides automatic priority heat allocation to the onds, control module attempts ignition sequence
indirect water heater for maximum response and again. Flame must prove within 5 attempts or
recovery. control will lockout (display will show [E 02]).
3. The water heater circulator continues for 30 seconds c. Verify flame failure operation by closing boiler
after the heating cycle to deliver the most possible manual gas cock to prevent gas flow. Open
heat. manual gas valve after testing.

B4
gas
Start-up — Gas boilers only (continued)

[3180] (burner on, space heating) Once flame is proven c. Verify flame failure operation by closing boiler
and stable, the burner turns down to low fire for ap- manual gas valve to prevent gas flow. Open gas
proximately 2 minutes. cock after testing.
• After this low fire period, the burner is allowed to [4180] (burner on, PLUS) Once flame is proven and
modulate. Firing rate depends on actual outlet water stable, the burner is allowed to modulate. Firing rate
temperature versus target temperature. depends on actual outlet water temperature versus
5. Allow boiler to bring water temperature to target target temperature.
temperature.
5. Allow boiler to bring water temperature to target
[6180] (target temperature reached) The burner will shut temperature.
down. The blower will run in postpurge (see below),
then turn off. The boiler circulator continues to run [6180] (target temperature reached) The burner will shut
as long as there is a call for heat. down. The blower will run in postpurge (see below),
then turn off. The PLUS circulator continues to run
6. Lower room thermostat to stop call for heat. as long as there is a call for PLUS heating.
[1180] (postpurge) When the room thermostat is satis-
fied (call for heat ended), the burner turns off. The 6. Lower PLUS aquastat to stop call for heat.
blower will continue for a 15-second postpurge, then [1180] (postpurge) When the room thermostat is satisfied
turn off. (If another call for heat occurs, the boiler will (call for heat ended), the burner turns off. The blower
remain off for one minute before starting again, and will continue for a 15-second postpurge, then turn off.
the display will show [6180].) (If another PLUS call for heat occurs, the boiler will
[0180] (no call for heat) Boiler is now in standby mode begin the heating cycle immediately.)
(waiting for heat call). [8180] (PLUS circulator run-on) The PLUS circulator
7. Repeat above steps several times to verify opera- continues to run for 30 seconds.
tion. [0180] (no call for heat) Boiler is now in standby mode
8. Return the room thermostat to normal setting. (waiting for heat call).
7. Repeat above steps several times to verify opera-
tion.
Verify water heater operation 8. Return the PLUS aquastat to normal setting.
1. Reconnect PLUS aquastat wiring to boiler if neces-
sary.
2. Turn off power to boiler at service switch. Operating information
3. Wait a few seconds, then turn on power to boiler. 1. To check operating conditions (actual and target
[A180] (self-check on power-up, for a few seconds) temperatures, for example), see Gas Boiler
[0180] (no call for heat) Manual for an explanation of the control
module Information mode.
4. Raise PLUS aquastat above tank temperature, to
call for heat. 2. During normal operation (no shutdown or lock-
[5180] (blower/circulator on) The blower and PLUS circu- out), the right 3 display digits show actual boiler
lator energize and the control checks for air flow. outlet water temperature.
[1180] (prepurge) Blower speed will increase to igni-
tion speed. The blower will run in prepurge for 10
seconds. Replace jacket front door
[2180] (ignition) After prepurge, the control module
opens the gas valve and starts ignition spark. Replace boiler jacket front door after
a. If burner flame proves within 4.5 seconds, burner installation or servicing. The boiler front
continues to fire. Burner will fire at start-up door must be securely fastened to the
rate — 50% of maximum input — for about 10 boiler to prevent boiler from drawing
seconds to allow flame to stabilize. air from inside the boiler room. This is
particularly important if the boiler is
b. If burner flame does not prove within 4.5 sec- located in the same room as other appli-
onds, control module attempts ignition sequence ances. Failure to keep the door securely
again. Flame must prove within 5 attempts or fastened could result in severe personal
control will lockout (display will show [E 02]). injury or death.

C Boiler-side piping (except Gas)
This section provides suggested boiler-side and system piping for boilers other than
Gas-fired boilers (see Section B for Gas applications). You will find suggested piping
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 D.
Zoning with pumps

GOLD PLUS 30/40/60/80 or PLUS 40/60/80
Two-pipe system piping — Figure 20........................................................................ 36
PLUS 100/110/119
Zoning with zone valves

Figure 23 (All water heater models)........................................................................... 39
Dedicated boiler applications

GOLD PLUS 30/40/60/80 or PLUS 40/60/80
Figure 24...................................................................................................................... 40
PLUS 100/110/119
Figure 25...................................................................................................................... 41
Multiple water heater applications

Multiple water heaters – water heater piping — Figures 26/27................................. 42
Boiler water piping for multiple water heaters — Figure 28...................................... 43
Connecting a water heater to a steam boiler

Figure 29...................................................................................................................... 45

C Boiler-side piping (except Gas) continued
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 manifold piping for total flow
of all zone pumps.
• Locate flow/check valves
as close as possible to water
heater boiler side connections
— to reduce heat loss between
cycles.
• Pipe GV boilers only as shown

on page 24.
Wiring options:
• Figure 30, page 48 — WMCR
zone controller, optional priority
• Figure 31, page 49 — Priority
zone pump
• Figure 32, page 50 — Pump
relays with domestic priority
relays without domestic priority
Notes 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.

Figure 21
GOLD Plus 30/40/60/80

Plus 40/60/80
• Primary/secondary piping

idle zones.
• Size primary circuit manifold for
total flow of all zone pumps, with
pressure drop of no more than 1
foot W.C.
• Locate flow/check valves
as close as possible to water
cycles.
Wiring options:
• Figure 30, page 48 — WMCR
zone controller, optional priority
• Figure 31, page 49 — Priority
zone pump
relays with domestic priority
relays without domestic priority

Figure 22
GOLD Plus 30/40/60/80

Plus 40/60/80
PLUS 100/110/119

• Primary/secondary piping

idle zones.
• Size primary circuit manifold for
total flow of all zone pumps, with
pressure drop of no more than 1
foot W.C.
Wiring options:
relays and 3-way priority valve
and priority relay

Figure 23
GOLD Plus 30/40/60/80

Plus 40/60/80
PLUS 100/110/119
• Zoning with zone valves

idle zones.
• Size manifold piping for total flow
of all zone pumps.
Wiring options:
• Figure 34, page 52 — WMZV
zone valve controller, priority
optional (priority valve not
required)
• Figure 40, page 58 or
Figure 41, page 59 — Priority
using 2-way valve
• Figure 37, page 55 or Figure
38, page 56 — Priority with
2-way priority valve and 2-way
zone valve on water heater
circuit
• Figure 35, page 53 or
Figure 36, page 54 — No
priority, using 2-way zone valve
on water heater circuit

Figure 24
Dedicated single boiler with

single water heater
In residential application (typically
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 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
3. Recommended piping for PLUS 100/110/119 water heaters used in residential applica-
tions.

Figure 25
Dedicated single boiler with

single water heater
In commercial application
(typically PLUS 100/110/119).
• Locate flow/check valve as close

as possible to water heater boiler
side connections — to reduce
heat loss between cycles.
3. Recommended piping for GOLD Plus 30/40/60/80 water heaters used in commercial
applications.

Figure 26
Multiple water heaters —

domestic water piping
Failure to install automatic mixing

valve where recommended can
result in severe personal injury or
death.
Notes 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.
3. Install automatic mixing valve at either the system hot water connection or at each water heater.
4. See pages 32-33 for additional recirculation information and piping detail.
Figure 27
Details for Figure 28, page 43

— alternate water heater piping
and Easy-Fit® Manifold detail

Figure 28
Multiple water heaters and

dedicated multiple boilers —
boiler water piping
(see legend and details in Figure 26,
page 42)
Notes 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.

ON STEAM BOILER APPLICATIONS ONLY — You must replace the automatic air vent
supplied with the water heater with a manual air vent. Failure to do so could result in severe
personal injury, death or substantial property damage.
Connecting water heater to Installation and start-up of

steam boiler water heaters connected to
When designing steam and domestic hot water sys- steam boilers
tems, there are some key issues that must be taken See Figure 29, page 45, for suggested piping schematic.
into consideration during the initial design phase. By Pipe the domestic water connections to the water heater
designing the system properly from the start, you can per Section A of this manual.
avoid problems and have a hot water loop in a steam
boiler system. • Boiler connections for the water heater must be
below the water line.
Special considerations: • For steam piping, refer to the boiler manual.
• Keep the loop temperature below the flash point. • Replace the automatic air vent furnished with the
Flashing can result in noise and circulator damage water heater with a manual air vent.
or shortened life.
• Wire the water heater and circulator to the boiler
• Be sure the loop is completely closed, with no au- per suggested wiring in Figure 29.
tomatic air vents or anything that could allow air
to enter the system when the pump shuts off. Use
manual air vents only to prevent the possibility of To fill the boiler and water heater:
flooding the boiler. • Close isolation valves 5 and 6 (Figure 29) to isolate
• Pipe supply from one side of the boiler, return to the boiler.
the opposite side. • Fill the boiler to the recommended water level per
• Supply from a tapping that is high enough to the boiler manual. Fill the domestic side of the water
prevent introducing sediment into the piping and heater per Section A of this manual.
circulator yet still positions the circulator below the • To fill the water heater outer tank with boiler water,
water line. Avoid the mud leg of the boiler. isolation valves 5 and 6 must remain closed. Valves
• Use an all bronze circulator (avoid wet rotor circula- 1 and 2 should be fully opened. Drain valves 3 and
tors). This will reduce clogging and will resist the 4 should also be fully opened.
corrosion potential from the steam condensate. • Open the water heater manual air vent to bleed the
• Make sure the circulator is properly sized. If the system of air.
pump runs too far out on the curve, cavitation Open the water heater manual air
potential increases significantly. vent one turn only.
• Return piping should be dedicated domestic re-
turn. • Fill the boiler/water heater system through drain
• Use (2) flow/check valves as shown to reduce the valve 3 until a steady stream of water flows through
potential for gravity circulation. Do not use spring- drain valve 4, initially purging the system of air.
loaded check valves in place of the flow/check valves • Continue to fill the boiler/water heater system while
shown in Figure 29 on page 45. closing drain valve 4.
• When drain valve 4 is fully closed and a steady
stream of water is exiting at the air vent, close the
manual air vent tightly. Drain valve 3 can now be
closed.
Water may spray from the manual
air vent.
• Open isolation valve 5 (at the front of the boiler).
Then open valve 6.
• Start the boiler per instructions given in the boiler
manual.

Figure 29
Steam boiler application

Domestic water heating using
water pumped from steam boiler
• Locate flow/check valve as

close as possible to water
cycles.
Use ball valve 7 to blend some of

the water returning to the boiler
with the hot water coming from the
boiler. This will reduce the possibil-
ity of flashing (cavitation) in the
circulator. Slowly open valve 7 until
temperature gauge 8 reads 200°F.
Lock or remove the handle from
valve 7 after adjusting.

D Boiler-side wiring & controls (except Gas)
This section provides suggested boiler-side wiring and control suggestions for boilers covered
in Section C of this manual. Section D does not apply to Gas-fired boilers, covered in
Section B. In Section D, you will find suggested wiring for:
• zoning with zone valves
• zoning with circulators
• wiring with and without domestic priority
• using separate relays or zone controllers
Make sure to use a compatible piping method as shown in the Section C. (Each wiring diagram
lists compatible piping alternatives.)
Wiring requirements............................................................................................... 47
Wiring requirements — Circulators............................................................................ 47
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.................................................................... 48
Other options for for zoning with pumps

• Using priority zone pump........................................................................................ 49
• Using pump relays • Domestic priority with priority relay................................. 50
• Using pump relays • No domestic priority.......................................................... 51
• Pumps relays • Domestic priority with 3-way priority valve & priority relay..... 60
Zoning with zone valves:

Zoning with Weil-McLain zone valve controller (WMZV)
• Domestic priority optional (controller switch)........................................................ 52

• No domestic priority................................................................................................ 53
• With or without priority • GOLD Plus 30/40/60/80 or Plus 40/60/80.......... 55
• With domestic priority • PLUS 100/110/119........................................................ 57
• With domestic priority using 2-way priority valve • PLUS 100/110/119............ 58

• No domestic priority................................................................................................ 54
• With or without priority • GOLD Plus 30/40/60/80 or Plus 40/60/80.......... 56
• With domestic priority • PLUS 100/110/119........................................................ 57
• With domestic priority using 2-way priority valve.................................................. 59

D Boiler-side wiring & controls (except Gas) continued
Electrical shock hazard.

Can cause severe personal injury, death or substantial property damage.
Disconnect power before installing and/or servicing.
Wiring requirements 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.
3. Refer to control component instructions packed with boiler for application information.
4. 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.
5. All electrical contacts are shown with no power applied - off shelf condition.
Circulators
6. Size priority relay for total amp draw of all circulators.
Zone Valves
7. Size transformer for maximum load of all zone valves.
8. Priority valve (Figures 40–41, pages 58–59) is closed when heating domestic water.
Domestic priority is recommended for the boilers listed in Table 5,

below, when used with GOLD Plus 30 water heaters:
Table 5 Boiler Models
These boiler models CGa 25/3/4/5/6/7/8

should use domestic
priority when used with GV, CGi, CG, CGs, CGx 3/4/5/6
heater GOLD Plus 30
EG 35/40/45/50
68, GO 2/3/4

Figure 30 Domestic water priority with Weil-McLain WMCR Circulator Zone Controller
Typical wiring:
• Weil-McLain circulator zone
controller (WMCR-4 shown)
• Refer to Wiring requirements on

page 47.
System piping —
Apply this wiring to systems
in:
• Figure 20, page 36
2. Follow component manufacturer’s instructions for installation of all items shown.

Figure 31
Typical wiring :
• Using priority zone pump
• Also refer to Weil-McLain

Boiler Zone Wiring Guide for
further details.

page 47.
System piping —
in:
Primary/secondary piping sys-

tems
Boiler loop pump (for primary/
secondary piping systems, as in Fig-
ure 21, page 37) should be powered
by the boiler control or transformer/
relay for packaged residential boilers.
Provide a pump relay for this pump
when pump relay is not provided
with boiler.
Pump zones
Maximum of 4 total pump zones
when wiring one zone for priority.

Figure 32
Typical wiring:
• Using pump relays
• Domestic priority with
priority relay

further details.

page 47.
System piping —
in:

tems
with boiler.

Figure 33
Typical wiring:
• Using pump relays
• No domestic priority

further details.

page 35.
System piping —
in:

tems
with boiler.

Figure 34 Domestic water priority with Weil-McLain WMZV Zone Valve Controller
Typical wiring:
• Zoning with Weil-McLain
zone valve controller
(WMZV-4 shown)
• Domestic priority optional
(controller switch)

further details.

page 47.
System piping —
in:
• Figure 23, page 39 (using 2-way
water heater zone valve and no
priority valve)
Install all zone valves per valve

manufacturer’s instructions.

Figure 35
Typical wiring:
• Zoning with 4-wire zone
valves

further details.

page 47.
System piping —
in:
priority valve)

Figure 36
Typical wiring:
valves

further details.

page 47.
System piping —
in:
priority valve)

Figure 37
Typical wiring:
valves
• With OR without domestic
priority
• GOLD Plus 30/40/60/80 or
Plus 40/60/80

further details.

page 47.
System piping —
in:
priority valve or NO priority using
2-way water heater zone valve
and no priority valve)

Figure 38
Typical wiring:
valves
• With OR without domestic
priority
• GOLD Plus 30/40/60/80 or
Plus 40/60/80

further details.

page 47.
System piping —
in:
priority valve or NO priority using
2-way water heater zone valve
and no priority valve)

Figure 39
Typical wiring:
• Zoning with zone valves
• With domestic priority
• PLUS 100/110/119 only

further details.

page 47.
System piping —
in:
priority valve)
4. Contact rating of water heater thermostat is 0.5 amp at 24 VAC.

Figure 40
Typical wiring:
valves
• With domestic priority using
2-way priority valve
• PLUS 100/110/119 only

further details.

page 47.
System piping —
in:
• Figure 23, page 39, (using 2-
way water heater zone valve and
2-way priority valve)

High voltage H 120 N

Figure 41
Transformer
V.A.C.
(Power)
Typical wiring: 24
• Zoning with 3-wire zone V.A.C.
valves Room
Zone valve
• With domestic priority using thermostat
2-way priority valve
Zone 1

further details. Room
Thermostat
• Refer to Wiring requirements on Zone 2

page 47.
Zone
System piping — valve

in: Additional zones may
Additional
• Figure 23, page 39 (using 2-way zones be added as shown above
water heater zone valve and 2-
way priority valve)
Priority valve
C
NC 2
NO 1
Contact not
Water heater Priority relay used
thermostat
Snap Set
Water heater Water heater

* Use Isolation Relay on zone zone valve
3-wire zone valves with
non-isolated end switches.
Transformer and boiler
control can burn out if
Isolation Relay is not used.
✱ Isolation
relay
Low voltage boiler field wiring

Boiler
Low voltage (24 vac) field wiring
thermostat
High voltage (120 vac) field wiring H N terminals 500075-30b

Figure 42
Typical wiring:
• Pump relays
• Domestic priority with 3-
way priority valve and priority
relay

further details.

page 47.
System piping —
in:

E Replacement parts — Series 3 only

A. GOLD Plus 30, 40, 60 or 80
Plus 40, 60 or 80
..................................................................................................................................... 50
B. PLUS 100, 110 or 119

..................................................................................................................................... 52

E Replacement parts continued

PLUS 40/60/80
Series 3

Replacement parts — GOLD Plus 30/40/60/80, Ultra Plus 40/60/80, Series 3
Item Description Size Manufacturer Weil-McLain Part

Number
1 Thermostat Kit with Knob - No Cover Plate Weil-McLain 633-900-130
not shown Drain Valve Kit Weil-McLain 633-900-117
Dip Tube Kit, GOLD Plus 30 ¾" Weil-McLain 633-900-118
Dip Tube Kit, GOLD Plus 40, Ultra PLUS 40 ¾" Weil-McLain 633-900-119
2
3 Snap-Set with Wire Connector Weil-McLain 635-600-145
4 Cover Plate and Plastic Fasteners Weil-McLain 633-900-200
not shown Thermostat with Cover Plate Kit Weil-McLain 633-900-102
5 Plastic Top Cover (specific to tank size) Weil-McLain 633-800-440
Drywell replacement kit, Gold Plus 30 Weil-McLain 635-600-061
Drywell replacement kit, Gold Plus 40, Ultra PLUS 40 Weil-McLain 635-600-062
6

PLUS 100/110/119
Series 3

Replacement parts — PLUS 100/110/119 Series 3
Weil-McLain Part
Item Description Size Manufacturer
Number
1 Thermostat Kit with Knob - No Cover Plate Weil-McLain 635-100-010
2 PLUS100/110/119 Dip Tube Kit 1½" Weil-McLain 633-900-115
3 Snap-Set with Wire Connector Weil-McLain 635-600-080
4 Cover Plate and Plastic Fasteners for 100/110/119 Weil-McLain 635-600-205
not shown Thermostat with Cover Plate Kit Weil-McLain 635-100-010
Plastic Top Cover (specific to tank size) 100/110 Weil-McLain 633-800-441

5 633-800-442
119 Weil-McLain
6 Dip Tube “O” Ring 1½" Weil-McLain 635-600-098
7 Drywell Replacement Kit for 100/110/119 Weil-McLain 635-600-065

F Water heater dimensions

Dimensions — PLUS-Line indirect water heaters, Series 3
PLUS-Line Indirect-Fired Water Heaters — Series 3
Water Storage Heating Head Dimensions Ship.

Heater surface loss on weight
Model DHW Boiler Boiler- DHW Boiler water A B C D E (approx.)
side side side inlet/outlet supply/return
(items 3 / 4) (items 1 / 2)
Gallons Gallons Sq. Feet Feet Inches NPT Inches NPT Inches Inches Inches Inches Inches Pounds
GOLD Plus 30 28 5 13 ¾ ¾ 1 38 9 30 22 ¼ 14 ¼ 135

GOLD Plus 40
Ultra Plus 40 36 6 16 1 ¾ 1 46 9 38 22 ¼ 14 ¼ 155
GOLD Plus 60
Ultra Plus 60 46 8 20 1¼ ¾ 1¼ 57 9 49 22 ¼ 14 ¼ 180
GOLD Plus 80
Ultra Plus 80 56 8 24 1½ ¾ 1¼ 66 9 58 ¼ 22 ¼ 14 ¼ 200
PLUS 100 70 14 29 2 1½ 1½ 61 10 50 ½ 26 ½ 10 ⁵⁄₈ 271
PLUS 110 95 25 34 2 1½ 1½ 78 10 67 ¼ 26 ½ 10 ⁵⁄₈ 362
PLUS 119 119 30 42 2½ 1½ 2 73 ¼ 10 63 32 ¼ 10 ⁵⁄₈ 479

F 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 Gas boiler
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
DOE
GOLD Boiler GOLD/ Boiler GOLD/ Boiler GOLD/ Boiler PLUS Boiler PLUS Boiler PLUS Boiler
Heating Water
Plus Ultra Water Ultra Water Ultra Water 100 Water 110 Water 119 Water
Capacity GPM GPM GPM GPM GPM GPM GPM
30 Plus Plus Plus
MBH Minimum Minimum Minimum Minimum Minimum Minimum Minimum
40 60 80
50 90 95 105 115 125 145 165
70 120 125 130 140 150 170 190
90 140 150 160 165 180 200 215
110 140 170 185 195 205 225 245
130 140 170 210 220 230 250 270
150 140 170 220 245 260 280 295
170 140 170 220 275 285 305 325
190 140 8 170 9 220 13 300 20 310 18 330 25 350 28
210 140 170 220 325 340 360 375
250 140 170 220 380 390 410 430
300 140 170 220 410 435 480 495
350 140 170 220 410 435 525 565
400 140 170 220 410 435 525 630
450 140 170 220 410 435 525 630
500 140 170 220 410 435 525 630
Boiler First Hour Rating Capacity (GPH) — Boiler Water Supply at 200°F / Domestic Water from 50°F to 115°F
DOE
GOLD Boiler GOLD/ Boiler GOLD/ Boiler GOLD/ Boiler PLUS Boiler PLUS Boiler PLUS Boiler
Heating Water
Plus Ultra Water Ultra Water Ultra Water 100 Water 110 Water 119 Water
Capacity GPM GPM GPM GPM GPM GPM GPM
30 Plus Plus Plus
MBH Minimum Minimum Minimum Minimum Minimum Minimum Minimum
40 60 80
50 115 125 130 140 150 170 190
70 155 160 170 175 185 205 225
90 190 195 205 215 225 245 265
110 230 235 240 250 260 280 300
130 230 260 280 285 300 320 335
150 230 260 315 325 335 355 375
170 230 260 355 360 370 390 410
190 230 8 260 9 365 13 400 20 410 24 430 26 450 28
210 230 260 365 435 445 465 485
250 230 260 365 510 520 540 560
300 230 260 365 600 610 630 650
350 230 260 365 670 690 725 745
400 230 260 365 670 690 775 835
450 230 260 365 670 690 775 930
500 230 260 365 670 690 775 970

Weil-McLain Limited Warranties
Residential & Commercial Cast Iron Boilers Indirect-Fired Water Heaters
 Residential Water Warranty — Limited Lifetime  Residential Water Heater Warranty — Limited Lifetime
 Residential Steam Warranty — Limited 10 Year  Commercial Water Heater Warranty — Limited 15 Year
 Commercial Warranty — Limited 10 Year First Year — (Residential and Commercial Water Heaters) Weil-McLain warrants
First Year — (All Residential & Commercial Cast Iron Boilers) Weil-McLain that its indirect-fired water heaters are free from defects in material and workmanship
warrants that its cast iron boilers are free from defects in material and workman- for one year from the date of installation. If any parts are found to be defective from
ship for one year from date of installation. If any parts are found to be defective such defects, Weil-McLain will provide replacement of such defective parts.
from such defects, Weil-McLain will provide replacement of such defective parts. Second Year and Beyond — (Residential Only)
Second Through Tenth Year — (Residential & Commercial Water/Steam) Second Through Fifth Years — (Commercial Only)
Weil-McLain warrants that the cast iron sections of its water and steam boilers are Weil-McLain warrants that the tank assembly components of its indirect-fired water
free from defects in material and workmanship from the date of installation for the heaters are free from defects in material and workmanship for the second through
second through the tenth year. If, during such time, any section is found to be the fifth year from the date of installation (commercial only), or for the second year
defective, Weil-McLain will provide replacement of such defective section(s). from the date of installation and beyond (for residential only). If, during such time
Eleventh Year and Beyond — (Residential Water Only) Weil-McLain warrants periods, a leak in the tank assembly should occur, Weil-McLain will provide replace-
that the cast iron sections of its residential water boilers are free from defects in ment for the original tank assembly.
material and workmanship for the eleventh year and beyond from the date of Sixth Ye ar through Fifteenth Ye ar — (Commercial Only) Weil-McLain warrants
installation. If, during such time period, any section(s) is found to be defective, that the tank assembly components of its commercial indirect-fired water heaters are
Weil-McLain will provide replacement of such defective section(s) upon the free from defects in material and workmanship for the sixth year through the fifteenth
payment of a proportionate charge based on the time the boiler has been in year following the date of installation. If, during such time period, a leak in the tank
service. The proportionate charge will be equal to the appropriate percentage of assembly should occur, Weil-McLain will provide replacement for such defective tank
the list price of such section(s) at the time the warranty claim is made, and will be assembly. Such replacement will be furnished with the nearest comparable model
determined as follows: 11th year-5%; 12th year-10%; 13th year-15%; 14th year- available from Weil-McLain at the time of such replacement and upon payment of a
20%; 15th year-25%; 16th year-30%; 17th year-35%; 18th year-40%; 19th year- proportionate charge. Proportionate charges will be equal to the appropriate percent-
45%; 20th year-50%; 21st year-55%; 22nd year-60%; 23rd year-65%; 24th year- age of the current list price of such commercial indirect-fired water heater at the time
70%; 25th year & beyond -75%. warranty claim is made and will be determined as follows: 6th & 7th year-55%; 8th &
These warranties do not cover boilers operated with combustion air contam- 9th year-60%; 10th & 11th year-65%; 12th & 13th year-70%; 14th & 15th year-75%.
inated externally by chemical vapors or with improper fuel additives, or with water These warranties do not cover:
conditions which may have caused unusual deposits in the cast iron sections. 1. Any water heater not initially installed with a new temperature-pressure relief valve
See section “For all Weil-McLain Products” for additional warranty information. bearing the listing of the American Society of Mechanical Engineers (A.S.M.E.) at the
time of the water heater installation.
Weil-McLain Ultra Cast Aluminum Boilers 2. Any water heater that has a failure or malfunction resulting from a.) failure to keep the
 Residential Warranty — Limited 15 Year (includes 5-Year Ultra Protection Plan) tank full of potable water; b.) failure to assure that water in the tank is free to circulate
at all times; or c.) failure to keep the tank free of water sediment or scale deposits.
 Commercial Warranty — Limited 15 Year (does NOT include Ultra HPP)
3. Any water heater that has potable water in the unit with a chloride or chlorine content
First Through Fifth Year — Weil-McLain warrants that its cast aluminum boilers higher than 80 mg/liter.
are free from defects in material and workmanship for one year from the date of 4. Any water heater installed in a residence containing any type of water softener system
installation and the heat exchanger is free from defects in material and that is not installed and maintained in accordance with manufacturer’s specifications.
workmanship for five years from the date of installation. If any parts in the first 5. Any water heater installation where non-metallic piping products without an oxygen
year, or the heat exchanger in the first five years are found to be defective from barrier are used.
such defects, Weil-McLain will provide replacement of such defective parts or heat 6. Any water heater used for non-potable application such as pool or process heating.
exchanger. In addition to the product warranty, Weil-McLain will provide a 5-Year “Ultra” See section “For all Weil-McLain Products” for additional warranty information.
Homeowner Protection Plan (“UHPP”) for residential applications only to cover parts and labor
for five years from the date of installation provided only if the Ultra boiler is properly registered Radiant Heating Products
with the UHPP Administrator within one month of the date of installation. UHPP claims must be
processed directly through the Plan Administrator and not through Weil-McLain.  Radiant Heating Products Warranty — Limited 30 Year
Sixth Through Tenth Year — Weil-McLain warrants that the heat exchangers of  IPP & IPC Products Warranty — Limited 3 Year
its cast aluminum boilers are free from defects in material and workmanship for Weil-McLain warrants that its AlumiPex and Qual-Pex radiant heating products are
the sixth through the tenth year from the date of installation. If, during such time, free from defects in material and workmanship for thirty years (three years for IPP
the heat exchanger is found to be defective, Weil-McLain will provide replacement and IPC products) from the date of installation. If any parts are found to be defective
of such defective heat exchanger. from such defects during such time period, Weil-McLain will provide replacement of
Eleventh Through Fifteenth Year — Weil-McLain warrants that the heat such defective parts. It is expressly understood that failure as a result of freezing of
exchangers of its cast aluminum boilers are free from defects in material and water within the pipes (tubing) does not constitute a defect in material or
workmanship for the eleventh through fifteenth year from the date of installation. workmanship and shall not be covered by this warranty.
If, during such time period, the heat exchanger is found to be defective, Weil- See section “For all Weil-McLain Products” for additional warranty information.
McLain will provide replacement for such defective heat exchanger upon the
payment of a proportionate charge based on the time the boiler has been in Parts and Accessories
service. The proportionate charge will be equal to the appropriate percentage of  Parts and Accessories Warranty — Limited 1 Year
the list price of such heat exchanger at the time the warranty claim is made, and Weil-McLain warrants that parts and accessories that were purchased through Weil-
will be determined as follows: 11t h year - 10%; 12th year - 20%; 13th year - McLain are free from defects in material and workmanship for one year from the date
40%; 14th year - 60%; 15th year - 80%; 16th year & beyond - 100%. of installation. If any parts and/or accessories are found to be defective from such
This warranty does not cover boilers operated with combustion air contaminated defects during such time period, Weil-McLain will provide replacement of such
externally by chemical vapors or with improper fuel additives, or with water/ defective parts. Parts and accessories covered under this warranty include only
system conditions which may have caused heat exchanger failure. those items that are not covered under other Weil-McLain product warranties.
See section “For all Weil-McLain Products” for additional warranty information. See section “For all Weil-McLain Products” for additional warranty information.
For All Weil-McLain Products: These warranties are subject to the condition NOTE: Residential warranties do not cover any residential products installed in build-
that the Weil-McLain Product(s) must have been installed in accordance with ings other than one or two family dwelling units, unless they are buildings with indi-
manufacturers’ instructions by a heating contractor whose principal occupation is vidual residential products for each dwelling unit.
the sale and installation of plumbing, heating and/or air conditioning equipment. THE WARRANTIES DESCRIBED HEREIN ARE IN LIEU OF ALL OTHER WAR-
These warranties extend only to the first retail purchaser of the products and only RANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IM-
to a product that has not been moved from its original installation site. PLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MER-
In addition to each product warranty listed, Weil-McLain warranties do not cover: CHANTABILITY. WEIL-McLAIN EXPRESSLY DISCLAIMS AND EXCLUDES ANY
1. Components that are part of the heating system (products) but were not fur- LIABILITY FOR CONSEQUENTIAL, INCIDENTAL, INDIRECT OR PUNITIVE DAM-
nished by Weil-McLain as a part of the heating system (products). AGES FOR BREACH OF ANY EXPRESS WARRANTY. For prompt product war-
2. The workmanship of any installer of Weil-McLain’s product(s). In addition, this ranty claims, notify the installer who, in turn, will notify the Weil-McLain distributor
warranty does not assume any liability of any nature for unsatisfactory perform- from whom he purchased the boiler. If this action does not result in warranty resolu-
ance caused by improper installation. tion, contact Weil-McLain Consumer Relations Department, 500 Blaine Street, Michi-
3. Any costs for labor for removal and reinstallation of the alleged defective part, gan City, Indiana 46360, with details in support of the warranty claim. Alleged defec-
transportation to Weil-McLain, if necessary, and any other materials necessary tive part or parts must be returned through the same trade channel in accordance
to perform the exchange. with the Weil-McLain procedure currently in force for handling returned goods for the
4. Any products that have a failure or malfunction resulting from improper or purpose of inspection to determine cause of failure. Weil-McLain will furnish new
negligent operation, accident, abuse, freezing, misuse, unauthorized alteration part(s) to an authorized Weil-McLain distributor who, in turn will furnish the new part
or improper repair or maintenance. (s) to the heating contractor who installed the boiler. If you have any questions about
5. Improper adjustments (including boiler/burner), control settings, care or mainte- the coverage of this warranty, contact Weil-McLain at the address above.
nance. Information is in the installation, start-up, operations, owner/user’s
manuals, service/maintenance instructions, and other printed/technical informa-
tion provided with the product or direct from Weil-McLain or weil-mclain.com.

Indirect Fired Water Heater Manual 1

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PLUS Line

Indirect-Fired Water Heaters

Manual • Installation • Maintenance

GOLD Plus 30/40/60/80

Read this page first

Indicates special instructions on installation, operation or maintenance

Read all instructions before installing. Failure to follow all instructions in

Hot Water Can Scald!

 Part Number PLUS-E017-A/1206

A. General installation (all water heaters)........................... 6

A2. Water heater piping

A3. Water heater wiring

A4. Water heater start-up

A5. Adjusting water heater temperature

A6. Water heater maintenance

A7. Recirculation and heat tracing

B. gas-fired boiler applications............................................... 24

B1. Install system water piping (space heating)

B2. Install boiler-to-water heater piping

B3. Field wiring — Gas-fired boilers only

B4. Start-up — Gas-fired boilers only

C. Boiler piping (except gas). ..................................................... 35

Zoning with pumps

Zoning with zone valves

Dedicated boiler applications

Multiple water heater applications

Steam boiler applications

D. Boiler-side wiring & controls (except gas)..... 46

Zoning with pumps:

Other options for for zoning with pumps

Zoning with zone valves:

Zoning with 4-wire zone valves

Zoning with 3-wire zone valves

F. Water heater dimensions & performance ratings

Part Number PLUS-E017-A/1206 

Location This water heater is not intended for outdoor installation.

 Part Number PLUS-E017-A/1206

Code restrictions National Standard Plumbing Code

Uniform Plumbing Code

Part Number PLUS-E017-A/1206 

A2 Water heater piping

 Part Number PLUS-E017-A/1206

A2 Water heater piping continued

An expansion tank may be required on

A2 Water heater piping continued

10 Part Number PLUS-E017-A/1206

A2 Water heater piping continued

An expansion tank may be required on

Part Number PLUS-E017-A/1206 11

A2 Water heater piping continued

An expansion tank may be required on

12 Part Number PLUS-E017-A/1206

A2 Water heater piping continued

Table 1 Water Connections Recommended Recirculation Dip Tube

If domestic water-side pressure exceeds 70 psig, install a pressure

Part Number PLUS-E017-A/1206 13

A2 Water heater piping continued

Do not use automotive, ethylene glycol or petroleum-based antifreeze. Do

14 Part Number PLUS-E017-A/1206

A3 Water heater wiring

Part Number PLUS-E017-A/1206

Part Number PLUS-E017-A/1206

Part Number PLUS-E017-A/1206

Part Number PLUS-E017-A/1206

Part Number PLUS-E017-A/1206