Weil-McLain Ultra Electric Water Heater Configuration guide

Thismanualmustonlybeusedbyaqualifiedheatinginstaller/servicetechnician.
Readallinstructions,includingtheBoilerManualandothersupplements,before
installing.InstallPLUSorUltraPLUSindirect-firedwaterheaterasexplainedin
thePLUSLineManual.InstallUltraboilerasexplainedintheUltraBoilerManual.
Performstepsintheordergiven.Failuretocomplycouldresultinseverepersonal
injury, death or substantial property damage.
Part No.IWHA016A/1103
Gas-firedWaterBoilers
with
PLUSPLUS
PLUSPLUS
PLUS LINELINE
LINELINE
LINE
Indirect-FiredWater Heaters
PLUS & PLUS water heaters with
Instruction Manual Supplement

Part number IWHA016A/1103
2
PLUS Line Instruction Manual Supplement
PLUS & PLUS WATER HEATERS WITH GAS-FIRED WATER BOILERS
Contents
The following defined terms are used throughout this manual to bring attention to the presence 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.
Hazard definitions ............................................................................... 2
Please read before proceeding........................................................... 2
1. Install system water piping ............................................................. 3
2. Install boiler-to-water heater piping................................................ 6
3.Fieldwiring ....................................................................................... 8
4.Start-up........................................................................................... 11
Hazard definitions
Please read before proceeding
Installer Read all instructions before installing.
Follow all instructions in proper order
to prevent personal injury or death.
• This document is intended only as a supplement
totheUltraBoilerManualandPLUSLinemanual.
It’s purpose is for connection of an Ultra boiler to
a PLUS Line water heater.
User
• This document is for use only by your qualified
heating installer/service technician.
• Please refer to the Ultra Boiler User’s Information
Manual for your reference.
• Keep this supplement near the boiler for use by
your installer or technician.
Follow the PLUS Line manual to install the PLUS water heater.
Ultra boilers must be installed as directed in the Ultra Boiler Manual and
supplements.
Failure to adhere to these guidelines can result in severe personal injury,
death or substantial property damage.

Part number IWHA016A/1103 3
PLUS Line Instruction Manual Supplement
PLUS & PLUS WATER HEATERS WITH GAS-FIRED WATER BOILERS
System water piping methods
Allpipingmethodsshowninthismanual
useprimary/secondaryconnectiontothe
boiler loop. These designs ensure proper
flowthroughtheUltraboiler,forthemost
efficientandreliableoperationoftheboiler
and the heating system. For other piping
methods,consultyourlocalWeil-McLain
representative or refer to separate Ultra
boilerpipingguides.
Wall-mounted boilers — Piping can exit
bottom of boiler enclosure. See separate
wall-mountinginstructionsfordetails.
Expansiontankandmake-upwater
1. Ensure expansion tank size will handle boiler and
system water volume and temperature. Allow 3
gallons for boiler and its piping.
Undersizedexpansiontankscausesystem
water to be lost from relief valve and
make-up water to be added through fill
valve. Eventual boiler failure can result
duetoexcessivemake-upwateraddition.
2. Tankmustbe located asshown inthissupplement,
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
connectionatthesamepointastheexpansiontank
connection to the system.
4. The piping drawings in this supplement show
diaphragmexpansiontanks.SeeFigure 1forpiping
from air separator to expansion tank and make-up
water line using a closed-type expansion tank.
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
airseparatortoremoveresidualairfromthesystem.
Closed-type expansion tank
1. See Figure 1 for piping connections when using a
closed-type expansion tank.
2. Pitchanyhorizontalpipinguptowardstank1 inch
per 5 feet of piping. Connect to tank with at least
¾" piping to allow room for air to rise.
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.
Install system water piping (space heating)1
Boiler circulator
Theboilercirculatorisshippedloose.Itmustbelocated
in either the return or supply piping, as shown in the
appropriate piping diagram in this supplement or the
BoilerManual.
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.
Sizing space heat system piping
1. SeeFigures 2and 3,pages 4and5,ortheUltraBoiler
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.
Figure 1 Expansion tank piping

Part number IWHA016A/1103
4
PLUS Line Instruction Manual Supplement
PLUS & PLUS WATER HEATERS WITH GAS-FIRED WATER BOILERS
Install system water piping (space heating) (continued)1
Figure 2 Zone valve zoning plus optional
water heater piping
Zoning with zone valves
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
sufficientflow.Italsoavoidsapplyingthehighhead
of the boiler circulator to the zone valves.
2. Whenusingaclosed-typeexpansiontank, 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 ControlModuleturnsoff
spaceheatingduringwaterheaterheating.
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.
Legend Figure 2
1 Ultra boiler
2 Indirect water heater (water heater), if used
3 Boiler relief valve (see boiler manual for piping details)
4 Reliefvalve discharge piping(see boiler manualfor details)
5 Water heater circulator (see page 7 for suggested sizing)
6 Isolation valves
7 System circulator
8 Diaphragm (or bladder) type expansion tank (see page 3
for piping of closed-type expansion tank, if used)
9 Airseparator [withautomatic air ventonly on systemsusing
diaphragm(or bladder) type expansiontank]
10 Flow/check valves (with weighted seats to prevent gravity
circulation)
11 Purge/drain valves
12 Boiler circulator
13 Zone valves, typical
20 Make-up water supply
21 Primary/secondary connection
NOTE1: To ensure adequate flow rate through the
boiler,usethefollowingpipesizeonallboiler
loop piping (connecting boiler to and from
theprimary/secondaryconnection,item21):
Ultra-80orUltra-105–1"orlarger.
Ultra-155orUltra-230–1¼"orlarger.
Ultra-310–1½"orlarger.
Useatleasttheminimumpipingsizeabove
and pipe the boiler using only primary/
secondary piping as shown. Failure to
follow these guidelines could result in
systemproblems.

Part number IWHA016A/1103 5
PLUS Line Instruction Manual Supplement
PLUS & PLUS WATER HEATERS WITH GAS-FIRED WATER BOILERS
Install system water piping (space heating) (continued)
Figure 3 Circulator zoning plus optional
water heater piping
Zoning with circulators
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. Whenusingaclosed-typeexpansiontank, 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 ControlModuleturnsoff
spaceheatingduringwaterheaterheating.
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.
NOTE1: To ensure adequate flow rate through the
boiler,usethefollowingpipesizeonallboiler
loop piping (connecting boiler to and from
theprimary/secondaryconnection,item21):
Ultra-80orUltra-105–1"orlarger.
Ultra-155orUltra-230–1¼"orlarger.
Ultra-310–1½"orlarger.
1
Legend Figure 3
1 Ultraboiler
2 Indirect water heater (water heater), if used
3 Boiler relief valve (see boiler manual for piping details)
4 Reliefvalve discharge piping(see boiler manualfor details)
5 Water heater circulator (see page 7 for suggested sizing)
6 Isolation valves
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]
10 Flow/check valves (with weighted seats to prevent gravity
circulation)
11 Purge/drainvalves
12 Boiler circulator
14 Zone circulators, typical
20 Make-up water supply
21 Primary/secondary connection
Useatleasttheminimumpipingsizeabove
and pipe the boiler using only primary/
secondary piping as shown. Failure to
follow these guidelines could result in
systemproblems.