L IN E
Indirect-Fired Water Heaters
P LU S
Instruction Manual Supplement
PLUS &
PLUS water heaters with
Gas-fired Water Boilers
with
This manual must only be used by a qualified heating installer/service technician.
Read all instructions, including the Boiler Manual and other supplements, before
installing. Install PLUS or Ultra PLUS indirect-fired water heater as explained in
the PLUS Line Manual.Install Ultra boiler as explained in the Ultra Boiler Manual.
Perform steps in the order given.Failure to comply could result in severe personal
injury, death or substantial property damage.
Part No.IWHA016A/1103
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P LU S Lin e In s t r u c t io n M a n u a l S u p p le m e n t
PLUS &
PLUS WATER HEATERS WITH
GAS-FIRED WATER BOILERS
1
In s t a ll s ys t e m w a t e r p ip in g (s p a c e h e a t in g )
System water piping methods
Figure 1 Expansion tank piping
All piping methods shown in this manual
use primary/secondary connection to the
boiler loop. These designs ensure proper
flow through the Ultra 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 Ultra
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
1. Ensure expansion tank size will handle boiler and
system water volume and temperature. Allow 3
gallons for boiler and its piping.
Undersized expansion tanks cause system
water to be lost from relief valve and
make-up water to be added through fill
valve. Eventual boiler failure can result
due to excessive make-up water addition.
2. Tank must be located as shown in this supplement,
or following recognized design methods. See tank
manufacturer’s instructions for details.
3. Connect the expansion tank to the air separator
only if the separator is on the suction side of the
system circulator. Always install the system fill
connection at the same point as the expansion tank
connection to the system.
4. The piping drawings in this supplement show
diaphragm expansion tanks. See Figure 1 for piping
from air separator to expansion tank and make-up
water line using a closed-type expansion tank.
Boiler circulator
The boiler circulator is shipped loose. It must be located
in either the return or supply piping, as shown in the
appropriate piping diagram in this supplement or the
Boiler Manual.
5. Refer to Ultra Boiler Manual for other system
piping examples.
Diaphragm (or bladder) expansion tank
1. Always install an automatic air vent on top of the
air separator to remove residual air from the system.
DO NOT use the boiler circulator in any
location other than those shown. The
boiler circulator is selected to ensure
adequate flow through the Ultra boiler.
Failure to comply could result in
unreliable performance and nuisance
shutdowns from insufficient flow.
Closed-type expansion tank
1. See Figure 1 for piping connections when using a
closed-type expansion tank.
2. Pitch any horizontal piping up towards tank 1 inch
per 5 feet of piping. Connect to tank with at least
¾" piping to allow room for air to rise.
Sizing space heat system piping
DO NOT install automatic air vents on
closed-type expansion tank systems. Air
must remain in the system and return to
the tank to provide its air cushion. An
automatic air vent would cause air to
leave system, resulting in water-logging
the expansion tank.
1. See Figures 2 and 3, pages 4 and 5, or the Ultra Boiler
Manual for recommended piping. In all diagrams,
the space heating system is isolated from the boiler
loop by the primary/secondary connection.
2. Size the piping and components in the space
heating system using recognized design methods.
3
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1
In s t a ll s ys t e m w a t e r p ip in g (s p a c e h e a t in g ) (continued)
Zoning with zone valves
Figure 2
Zone valve zoning plus optional
water heater piping
1. Connect boiler to system as shown in Figure 2
when zone valve zoning. The primary/secondary
piping shown ensures the boiler loop will have
sufficient flow. It also avoids applying the high head
of the boiler circulator to the zone valves.
2. When using a closed-type expansion tank, connect
the expansion tank and make-up water piping as
shown in Figure 1, page 3.
3. Connect water heater (domestic hot water) piping
to indirect storage water heater as shown.
The
PhD Control Module turns off
space heating during water heater heating.
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
gravity circulation in the boiler loop
during water heater heating.
4. Controlling the system circulator
a. To cycle the system circulator from the Ultra PhD
control module, add a circulator relay wired to the
boiler circulator terminals as shown on page 8.
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):
Ultra-80 or Ultra-105 – 1" or larger.
Ultra-155 or Ultra-230 – 1¼" or larger.
Ultra-310 – 1½" or larger.
Use at least the minimum piping size above
and pipe the boiler using only primary/
secondary piping as shown. Failure to
follow these guidelines could result in
system problems.
Legend
Figure 2
1
2
3
4
5
6
7
8
Ultra boiler
10 Flow/check valves (with weighted seats to prevent gravity
circulation)
Indirect water heater (water heater), if used
Boiler relief valve (see boiler manual for piping details)
Relief valve discharge piping (see boiler manual for details)
Water heater circulator (see page 7 for suggested sizing)
Isolation valves
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, typical
20 Make-up water supply
21 Primary/secondary connection
System circulator
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]
4
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P LU S Lin e In s t r u c t io n M a n u a l S u p p le m e n t
PLUS &
PLUS WATER HEATERS WITH
GAS-FIRED WATER BOILERS
1
In s t a ll s ys t e m w a t e r p ip in g (s p a c e h e a t in g ) (continued)
Zoning with circulators
Figure 3
Circulator zoning plus optional
water heater piping
1. Connect boiler to system as shown in Figure 3
when circulator zoning. The boiler circulator
cannot be used for a zone. It must supply only the
boiler loop.
2. Install a separate circulator for each zone.
3. When using a closed-type expansion tank, connect
the expansion tank and make-up water piping as
shown in Figure 1, page 3.
4. Connect water heater (domestic hot water) piping
to indirect storage water heater as shown.
The
PhD Control Module turns off
space heating during water heater heating.
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
gravity 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):
Ultra-80 or Ultra-105 – 1" or larger.
Ultra-155 or Ultra-230 – 1¼" or larger.
Ultra-310 – 1½" or larger.
Use at least the minimum piping size above
and pipe the boiler using only primary/
secondary piping as shown. Failure to
follow these guidelines could result in
system problems.
Legend
Figure 3
1
2
3
4
5
6
7
8
Ultra boiler
10 Flow/check valves (with weighted seats to prevent gravity
circulation)
Indirect water heater (water heater), if used
Boiler relief valve (see boiler manual for piping details)
Relief valve discharge piping (see boiler manual for details)
Water heater circulator (see page 7 for suggested sizing)
Isolation valves
11 Purge/drain valves
12 Boiler circulator
14 Zone circulators, typical
20 Make-up water supply
21 Primary/secondary connection
System circulator
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]
5
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PLUS WATER HEATERS WITH
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2
In s t a ll b o ile r-t o -w a t e r h e a t e r p ip in g
Combined space heating/water
heating applications
Dedicated water-heating only
applications
1. Figure 4 shows recommended piping between Ultra 1. Figure 5 shows recommended piping between Ultra
Boiler and PLUS water heater. All show direct
connection of the water heater piping to the boiler
because the boiler circulator shuts down during
water heater operation.
Plus Boiler and PLUS water heater for dedicated
water-heating only applications.
2. Pipe sizing:
Table 2, page 7, provides the recommended
minimum pipe size for boiler-to-water heater piping.
3. Circulator:
Use the circulator recommended in Table 2, page 7.
Install the circulator as shown in Figure 5.
4. Procedure:
2. Table 1, page 7, uses the recommended flow rates
for the Ultra PLUS water heater and minimum flow
rates for the Ultra boiler to provide recommended
water heater piping and circulator sizing. If using
another circulator, verify it is at least equal to the
Taco selection given in Table 1. For general
information on head loss through boiler and boiler-
to-water heater piping, refer to the Ultra Boiler
Manual.
Step 1: Select Ultra Boiler model and PLUS water
heater model in Table 1,page 7.
Step 2: Read flow rate expected using the circulator
3. Procedure:
specified inthe last column.
Step 1: Select Ultra Boiler model and PLUS water
heater model in Table 1.
Step 3: Size connecting piping as listed under
“Boiler piping” in the table.
Step 2: Read recommended minimum flow rate, GPM,
in table.
Step 3: Read across to find recommended minimum
pipe size 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 6, page 7 for pump curves of typical
Taco circulators.
Figure 4 Boiler-to-water heater piping:
Combined space heating/water
heating application
Figure 5 Boiler-to-water heater piping:
Dedicated water-heating only
application
3
4
5
Boiler relief valve (see Boiler Manual for piping details)
Relief valve discharge piping (see Boiler Manual for details)
Water heater circulator — must be at least equal in capacity to
circulator recommended in Table 1, page 7
3
4
5
8
6
Boiler relief valve (see Boiler Manual for piping details)
Relief valve discharge piping (see Boiler Manual for details)
Water heater circulator — (see Table 2, page 7)
Expansion tank (diaphragm or bladder type)
Isolation valves
6
Isolation valves
10 Flow/check valve (with weighted seat to prevent gravity circulation)
11 Purge/drain valves
10 Flow/check valve (with weighted seat)
11 Purge/drain valve
20 Fill line to fill valve (item 23)
6
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PLUS &
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2
In s t a ll b o ile r-t o -w a t e r h e a t e r p ip in g
(continued)
Table 1
Combined space heating/water heating applications (see Notes)
Table 2
Dedicated water-heating only systems (using circulator supplied with boiler) (see Notes)
Notes
Tables 1 and 2
Figure 6
Pump curves for Taco circulators
1. First hour ratings in Tables 1 and 2 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 Ultra 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.
7
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3
Fie ld w irin g
ELECTRICAL SHOCK HAZARD —
Line voltage connections
For your safety, turn off electrical power
supply at service entrance panel before
making any electrical connections to
avoid possible electric shock hazard.
Failure to do so can cause severe personal
injury or death.
1. Connect 120 VAC power wiring to line voltage
terminal strip in left compartment of electrical
entrance, as shown in Figure 7, item 1.
2. Provide and install a fused disconnect or service
switch (15 amp. recommended) as required by the
code. (See Figure 7, item 2)
Wiring must be N.E.C. Class 1.
If original wiring as supplied with boiler
must be replaced, use only type 105 °C
wire or equivalent.
Wiring boiler circulator
1. The Taco 0011 circulator supplied with the boiler
is wired one of two locations, depending on
whether system is combined space heating/water
heating or dedicated water-heating only. Boiler
circulator is shipped loose. Wire Boiler circulator
to terminals (refer to Figure 7):
Boiler must be electrically grounded as
required by National Electrical Code
ANSI/NFPA 70 – latest edition.
a. Combined system: terminals 5, 6, and 7 (installed as
Figure 7, item 3).
b. Dedicated system: terminals 3, 4, and ground wire nut
(installed as Figure 7, item 5).
Installation must comply with:
1. National Electrical Code and any other national,
state, provincial or local codes or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code
Part 1, and any local codes.
Wiring PLUS circulator
1. For combined systems, connect water heater
circulator to line voltage terminal strip terminals 3,
4 and ground wire nut. See Figure 7.
Figure 7 Line voltage field wiring connections (service switch provided by installer)
8
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3
Fie ld w irin g
(continued)
Wiring a system circulator
switch is closed, boiler will attempt to maintain
constant temperature.)
5. Route sensor wires through the grommeted hole
at right of the electrical entrance (see Figure 8).
1. For combined systems, to activate a system
circulator when the Boiler circulator operates, wire
as shown at bottom of Figure 7, page 8.
2. You must install a relay as shown. DO NOT wire in
parallel with the Boiler circulator. See CAUTION
in Figure 7.
PLUS water heater thermostat
1. Connect PLUS water heater aquastat terminals“C”
and “1” to Ultra Boiler low voltage terminal strip
between terminals 3 and 4 (Figure 9, item 3).
Routing line voltage wiring
1. Route line voltage connections to the jacket
openings shown in Figure 8.
Additional limits
1. Connect additional limit controls and interlocks
between the terminals shown in Figure 9.
Low voltage connections (Fig. 9)
2. Controls connected between terminals 6 and 7 (see
Figure 9, item 4) will cause a soft lockout
(automatic reset). When limit(s) closes, boiler will
resume normal operation.
3. Controls connected between terminals 6 and 8 (see
Figure 9, item 5.) will cause a hard lockout (manual
reset). The boiler will only restart after the Ultra
display panel RESET switch is pressed.
1. Connect low voltage wiring to low voltage terminal
strip (Figure 9, item 1) as shown in Figure 9 and
the boiler wiring diagram.
2. Route all low voltage wires through grommeted
jacket opening to right of low voltage terminal strip,
as shown in Figure 8.
Room thermostat (space heating)
1. For combined space heating/water heating systems,
connect Figure 9, item 2, room thermostat or end
switch (isolated contact only) between terminals 5
Figure 8 Routing field wiring
and 6.
2. Install thermostat on inside wall away from
influences 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 9,
item 6) between terminals 1 and 2 to enable
outdoor reset operation of the Ultra boiler. If fixed-
temperature operation is required, do not install
outdoor sensor.
3. Mount sensor on exterior wall, shielded from direct
sunlight or flow of heat or cooling from other
sources.
4. Install a summer/winter switch (Figure 9, item 7)
across terminals 1 and 2 to force fixed-temperature
operation during summer months. (When the
9
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3
Fie ld w irin g
(continued)
Figure 9 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.
10
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4
S t a rt-u p
Follow Boiler Manual procedures
Check PLUS operation setup
1. Follow all procedures in the boiler manual to start 1. Go to step 2 if the control is in Parameter mode
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
shows “2.”
Set space heating operation
Verify space heating mode
1. Press the “Mode” button until the display shows
“Para.” This is the parameter mode.
2. Press the “Step” button until the display first digit
shows “3.”
3. The last digit must show “1.” If any other number
displays, press the “+” button until “1” shows in
the right-hand digit.Press the“Store”button to save
this setting.
3. The last digit must show “1.” If any other number
displays, press the “+” button until “1” shows in
the right-hand digit. Press the“Store”button to save
this setting.
4. The Ultra PhD control module turns on the PLUS
circulator when the indirect water heater operating
control closes. The control module shuts off the
boiler circulator (stops space heating) during calls
for DHW heating.
Set space heating target temperature
Verify operation — space heating
1. Press the Ultra control panel“Step”button until the
display first digit shows“4.”The right 3 digits show
the outlet water temperature setting.
2. Press the “+” or “-” button to change the setting to
the desired outlet water temperature. (The factory
default setting is 190 °F.)
NOTE: “[ _ _ _ _ ]” in the following indicates the
characters that should show on the Ultra display panel.
“180” in the right 3 places means the display shows the
measured boiler water temperature. The number shown
will not necessarily be 180.
a. Outdoor sensor installed — Setting is the target
temperature for outdoor temperature at or below
32 °F. At higher outside temperatures, the Ultra PhD
control module calculates the target temperature. (See
Ultra Control Supplement for detailed discussion of
outdoor reset.)
1. Turn down aquastat on PLUS tank. If necessary, turn
off power and remove one of the PLUS aquastat
wires to ensure boiler will not receive a DHW heat
call.
2. Turn off power to boiler at service switch.
When asummer/winter switch isused, closingtheswitch
will disable the boiler (space heating) circulator during
summer operation.
3. Wait a few seconds, then turn on power to boiler.
[A180] (self-check on power-up, for a few seconds)
[0180] (no call for heat)
b. Outdoor sensor not installed — Setting is the target
temperature at all times.
4. Raise room thermostat to call for heat.
[5180] (blower/circulator on) The blower and boiler
circulator 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.
3. Press the “Store” button to save the setting.
PLUS water heater operation
1. The PLUS water heater thermostat must be
connected to low voltage terminal strip terminals 3
and 4 as shown on page 10.
2. When the water heater thermostat calls for heat, the
module shuts down the boiler circulator, activates
the water heater circulator and immediately sets
target outlet water temperature to 190°F. This
provides automatic priority heat allocation to the
indirect water heater for maximum response and
recovery.
[2180] (ignition) After prepurge, the control module
opens the gas valve and starts ignition spark.
a. If burner flame proves within 4.5 seconds, burner
continues to fire. Burner will fire at start-up rate
— 50% of maximum input — for about 10
seconds to allow flame to stabilize.
b. If burner flame does not prove within 4.5 seconds,
control module attempts ignition sequence again.
Flame must prove within 5 attempts or control
will lockout (display will show [E 02]).
3. The water heater circulator continues for 30
seconds after the heating cycle to deliver the most
possible heat.
c. Verify flame failure operation by closing boiler
manual gas cock to prevent gas flow.Open manual
gas valve after testing.
11
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4
S t a rt-u p
(continued)
[3180] (burner on, space heating) Once flame is proven
and stable, the burner turns down to low fire for
approximately 2 minutes.
c. Verify flame failure operation by closing boiler
manual gas valve to prevent gas flow. Open gas
cock after testing.
•
After this low fire period, the burner is allowed to
modulate. Firing rate depends on actual outlet water
temperature versus target temperature.
[4180] (burner on, PLUS) Once flame is proven and stable,
the burner is allowed to modulate. Firing rate depends
on actual outlet water temperature versus target
temperature.
5. Allow boiler to bring water temperature to target
temperature.
5. Allow boiler to bring water temperature to target
temperature.
[6180] (target temperature reached) The burner will shut
down. The blower will run in postpurge (see below),
then turn off. The boiler circulator continues to run as
long as there is a call for heat.
[6180] (target temperature reached) The burner will shut
down. The blower will run in postpurge (see below),
then turn off. The PLUS circulator continues to run as
long as there is a call for PLUS heating.
6. Lower room thermostat to stop call for heat.
[1180] (postpurge) When the room thermostat is satisfied
(call for heat ended), the burner turns off. The blower
will continue for a 15-second postpurge, then turn off.
(If another call for heat occurs, the boiler will remain
off for one minute before starting again, and the display
will show [6180].)
6. Lower PLUS aquastat to stop call for heat.
[1180] (postpurge) When the room thermostat is satisfied
(call for heat ended), the burner turns off. The blower
will continue for a 15-second postpurge, then turn off.
(If another PLUS call for heat occurs, the boiler will
begin the heating cycle immediately.)
[0180] (no call for heat) Boiler is now in standby mode
(waiting for heat call).
[8180] (PLUS circulator run-on) The PLUS circulator
continues to run for 30 seconds.
7. Repeat above steps several times to verify
operation.
[0180] (no call for heat) Boiler is now in standby mode
(waiting for heat call).
8. Return the room thermostat to normal setting.
7. Repeat above steps several times to verify
operation.
8. Return the PLUS aquastat to normal setting.
Verify operation — PLUS water
heater
Operating information
1. Reconnect PLUS aquastat wiring to boiler if
necessary.
2. Turn off power to boiler at service switch.
3. Wait a few seconds, then turn on power to boiler.
[A180] (self-check on power-up, for a few seconds)
[0180] (no call for heat)
4. Raise PLUS aquastat above tank temperature,to call
for heat.
1. To check operating conditions (actual and target
temperatures, for example), see page 40 in Ultra
Boiler Manual for an explanation of the Ultra
control module Information mode.
2. During normal operation (no shutdown or
lockout), the right 3 display digits show actual boiler
outlet water temperature.
[5180] (blower/circulator on) The blower and PLUS
circulator energize and the control checks for air flow.
[1180] (prepurge) Blower speed will increase to ignition
speed. The blower will run in prepurge for 10 seconds.
[2180] (ignition) After prepurge, the control module
opens the gas valve and starts ignition spark.
Replace boiler jacket front door
Replace boiler jacket front door after
installation or servicing. The boiler front
door must be securely fastened to the
boiler to prevent boiler from drawing air
from inside the boiler room. This is
particularly important if the boiler is
located in the same room as other
appliances. Failure to keep the door
securely fastened could result in severe
personal injury or death.
a. If burner flame proves within 4.5 seconds, burner
continues to fire. Burner will fire at start-up rate
— 50% of maximum input — for about 10
seconds to allow flame to stabilize.
b. If burner flame does not prove within 4.5 seconds,
control module attempts ignition sequence again.
Flame must prove within 5 attempts or control
will lockout (display will show [E 02]).
12
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