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

Part Number PLUS-E017-A/1206
User — Read important user safety information found on pages 2, 18, 19 and 20. Installation and service should only
be performed by a qualified service technician. Retain this manual for future reference.
P lus 40/60/80
Plus 100/110/119
• Installation
• Startup
• Maintenance
• Parts
Manual
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.
Indirect-Fired Water Heaters
Series 3
PLUS Line
GOlD P lus 30/40/60/80

2Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
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.
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.
Hazard
definitions
The following defined terms are used throughout this manual to bring attention to the pres-
ence of hazards of various risk levels, or to important information concerning the life of the
product.
Indicates presence of hazards that will cause severe personal injury, death
or substantial property damage.
Indicates presence of hazards that can cause severe personal injury, death
or substantial property damage.
Indicates presence of hazards that will or can cause minor personal injury
or property damage.
Indicates special instructions on installation, operation or maintenance
that are important but not related to personal injury or property
damage.
Read this page first

Part Number PLUS-E017-A/1206 3
Manual • Installation • Start-Up • Usage • Maintenance • Parts
Overview
This manual contains six sections, A through F.
Sections A, E and Fapply 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 Agives guidelines for domestic water connections to the water
heater. Section Elists replacement parts. Section Fincludes 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 Dprovide 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
Contents
(continued on next page)

4Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
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
Primary/secondary piping — Figure 22..................................................................... 38
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
Contents continued
(continued on next page)

Part Number PLUS-E017-A/1206 5
Manual • Installation • Start-Up • Usage • Maintenance • Parts
PLUS 100/110/119
Figure 25 ..................................................................................................................... 41
Multiple water heater applications
Multiple water heaters – water heater piping — Figures 26/27................................ 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
Zoning with 3-wire zone valves
• 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
Contents continued

6Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
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.
Recommended
clearances
Installation location must provide adequate clearances for servicing and proper operation of
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.
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.
Figure 1
Clearance recommendations
A1 Pre-installation

Part Number PLUS-E017-A/1206 7
Manual • Installation • Start-Up • Usage • Maintenance • Parts
Operating
restrictions
• Maximum domestic hot water temperature (Use only for special high-temperature
operational requirements):
• 160°F for GOLD Plus 30/40/60/80 or Plus 40/60/80.
• 190°F for 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.
A1 Pre-installation continued

8Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Temperature &
pressure (T & P)
relief valve
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.
To reduce risk of excessive pressures and temperatures in water heater,
install temperature and pressure protective equipment required by local
codes, but no less than a combination temperature and pressure relief
valve certified by a nationally recognized testing laboratory that main-
tains periodic inspection of production of listed equipment or materials,
as meeting the requirements for Relief Valves and Automatic Gas Shutoff
Devices for Hot Water Supply Systems, ANSI Z21.22. This valve must be
marked with a maximum working pressure of the water heater.
A2 Water heater piping
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.

Part Number PLUS-E017-A/1206 9
Manual • Installation • Start-Up • Usage • Maintenance • Parts
Figure 2
Piping — OPTION 1
GOLD Plus 30/40/60/80 or
Plus 40/60/80
(See Figure 3, page 10, for Option 2,
required for Massachusetts)
Drain valve
GOLD Plus 30/40/60/80
Option 1
Apply the following and Figure 2 to water heaters other than those installed in Massachusetts.
For Commonwealth of Massachusetts installations, see Option 2, Figure 3, page 9.
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).
Water heater piping continuedA2
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.

10 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Water heater piping continuedA2
Figure 3
Piping — OPTION 2
Models 30/40/60/80 or
Plus 40/60/80
(Required for Commonwealth of
Massachusetts)
Drain valve
GOLD Plus 30/40/60/80
or Plus 40/60/80
Option 2
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.
1. Insert a close nipple and then an open-ended “draining” dip tube into the AUX tapping
on top of the heater.
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.
An expansion tank may be required on
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.
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.

Part Number PLUS-E017-A/1206 11
Manual • Installation • Start-Up • Usage • Maintenance • Parts
Figure 4
Piping — OPTION 1
PLUS 100/110/119
(See Figure 5, page 12, for OPTION 2,
required for Massachusetts)
Drain valve
PLUS 100/110/119
Option 1
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.
1. Install a brass tee in the domestic water inlet piping using suitable pipe dope or tape, located
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.
An expansion tank may be required on
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.
Water heater piping continuedA2
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.

12 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Figure 5
Piping — OPTION 2
PLUS 100/110/119
(Required for Commonwealth of
Massachusetts)
Drain valve
PLUS 100/110/119
Option 2
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.
1. Insert an open-ended “draining” dip tube into the AUX tapping on top of the heater.
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.
Water heater piping continuedA2
An expansion tank may be required on
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.
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.

Part Number PLUS-E017-A/1206 13
Manual • Installation • Start-Up • Usage • Maintenance • Parts
General piping
information
• For domestic water piping, see pages 8 through 12.
• 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.
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.
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.
Table 1
Piping (Inches NPT)
Water
Heater
Model
Connections Recommended
Piping Between
Water Heater
and Boiler
Recirculation Dip Tube
Domestic
Water
Inlet/Outlet
Boiler Water
Supply/
Return
Length
(inches)
Diameter
(inches)
30 ¾ 1 1 34 ¾
40 ¾ 1 1 42 ¾
60 ¾ 1 ¼ 1 ¼ 52 ¾
80 ¾ 1 ¼ 1 ½ 61 ¾
100 1 ½ 1 ½ 1 ½ 25 1 ½
110 1 ½ 1 ½ 1 ½ 32 1 ½
119 1 ½ 2 2 32 1 ½
Water heater piping continued
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.
A2

14 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Domestic water
piping
• Union on domestic hot water outlet should be piped at a higher elevation than domestic
water drain valve. This will make draining water heater easier.
• Install unions for easy removal of water heater. Use dielectric unions or couplings to protect
hot and cold water fittings from corrosion when connecting dissimilar materials such as
copper and galvanized iron pipe.
• If copper pipe is used for domestic water connections,first solder pipe to a threaded adapter,
and then screw adapter into cold water inlet on top of water heater. Inlet contains an
internal plastic dip tube rated at 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,
death or substantial property damage.
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,
death or substantial property damage.
Water heater piping continuedA2

Part Number PLUS-E017-A/1206 15
Manual • Installation • Start-Up • Usage • Maintenance • Parts
Water heater
thermostat
connection
PLUS-Line indirect water heaters utilize a snap-set connector for easy wiring between water
heater thermostat and boiler controls (also see Section B or D). See Figure 6, below.
Figure 6
Thermostat connection
Water heater wiring
Terminal 1of the snap-set is the normally-open contact; terminal 2is the
normally-closed contact; terminal Cis common.
A3

16 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
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.
Filling the inner
(domestic water)
tank
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.
• Inner tank must be completely filled and pressurized before pres-
surizing outer tank.
• Never use water heater unless inner and outer tanks are completely filled
with water.
Filling the outer
(boiler water) tank
Figure 7
Open cap on air vent to allow air
to escape from outer tank
Do not use automotive, ethylene glycol or petroleum-based antifreeze. Do
not use any undiluted antifreeze. This can cause severe personal injury,
death or substantial property damage if ignored.
Water heater start-up
A
B
6406-6
• Inner tank must be completely filled and pressurized before pres-
surizing outer tank.
• Never use water heater unless inner and outer tanks are completely filled
with water.
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.
A4

Part Number PLUS-E017-A/1206 17
Manual • Installation • Start-Up • Usage • Maintenance • Parts
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
Water heater start-up continued
A4

18 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
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.
Adjusting water heater temperatureA5

Part Number PLUS-E017-A/1206 19
Manual • Installation • Start-Up • Usage • Maintenance • Parts
Studies have indicated that dangerous bacteria, including legionella pneumophila, can form in the potable
water distribution system if certain minimum water temperatures are not maintained. Contact your local
health department for more information.
Setting the thermostat
GOLD Plus 30/40/60/80
or Plus 40/60/80
Setting the thermostat
PLUS 100/110/119
Water heater thermostat is factory set to its lowest tem-
perature. The arrowhead indicator on the label is the
preferred starting point for setting temperature. This may
or may not be suitable for your needs.
Turn thermostat knob clockwise to increase water
temperature.
Turn thermostat knob counter-clockwise to reduce
water temperature.
When decreasing temperature setting, the stored hot water
must be used before checking temperature at faucet.
Check water temperature at a hot water faucet immediately
after first heating cycle. Further temperature adjustment
may be necessary as water heating system is used. Recheck
water temperature at faucet after adjustment.
When adjusting thermostat, be sure boiler limit control is
set a minimum 20°F higher.
Water heater thermostat is factory set to its lowest tem-
perature. The white factory setting mark on the label is the
preferred starting point for setting temperature. This may
or may not be suitable for your needs.
Turn thermostat knob clockwise to increase water
temperature.
Turn thermostat knob counter-clockwise to reduce
water temperature.
When decreasing temperature setting, the stored hot water
must be used before checking temperature at faucet.
Check water temperature at a hot water faucet immediately
after first heating cycle. Further temperature adjustment
may be necessary as water heating system is used. Recheck
water temperature at faucet after adjustment.
When adjusting thermostat, be sure boiler limit control is
set a minimum 20°F higher.
At no time should boiler limit control be
set above 210°F. This can cause severe
personal injury, death or substantial
property damage if ignored.
At no time should boiler limit control be
set above 210°F. This can cause severe
personal injury, death or substantial
property damage if ignored.
Adjusting water heater temperature continued
Factory Setting
A5

20 Part Number PLUS-E017-A/1206
PLUS LINE Indirect-Fired Water Heaters – Series 3
Water heater maintenanceA6
Maintenance
schedule – annual
service technician
Annual service by qualified service technician to include:
• Any procedures required by local codes.
• Check air vent operation.
• Verify system pressure. Air venting procedure may require adding water to bring system
up to pressure, typically 12 psig.
• Manually operate T&P relief valve at least once a year. This will release some hot water.
• 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.
• 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.
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.
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.
Maintenance
schedule – monthly
homeowner
Homeowner monthly maintenance to include:
• Check air vent operation:
• 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.
• Visually check valves, pipes and fittings for leaks. Call qualified service technician to repair
leaks.
Figure 8
Remove air vent cap to check
operation
6406-10
A
B
6406-6