Weil-McLain WM97+110 Manual Download Page 6

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Part number 550-142-085/0712

WM97+

gas

fired

water

boiler

—

Boiler Manual

– 6 –

Contents

The WM97+70 & 110 Gas-fired water boilers 2

The WM97+155 Gas-fired water boiler 4

Please read before proceeding 7

Boiler location 8

Wall-mounting the boiler 10

Boiler hydrostatic test 12

Converting boiler to propane — WM97+70/110 14

Converting boiler to propane — WM97+155 16

Gas piping — sizing gas lines 18

Venting/air piping — general 19

Commonwealth of Massachusetts installations 22

Vent termination requirements 23

Boiler room air openings 24

DIRECT VENT — Sidewall with W-M vent/air plate 25

DIRECT VENT — Sidewall with separate pipes 27

DIRECT VENT — Sidewall concentric 29

DIRECT VENT — Vertical with separate pipes 31

DIRECT VENT — Vertical concentric 33

Concentric termination, typical (sidewall or vertical) 35

Vent and air piping and boiler connections 36

Install water piping 37

Internal water piping — WM97+70 and 110 38

Internal water piping — WM97+155 39

Expansion tank — WM97+70 and 110 40

Expansion tank — WM97+155 41

System piping 42

Multiple boiler installations 54

Install condensate line 60

Gas piping 61

Field wiring 62

Wiring diagram — schematic 65

Wiring diagram — ladder 66

EXPRESS SETUP — using default settings 67

WM97+ control operation 69

ESSENTIAL settings 71

WM97+ control settings 72

BOILER SETTINGS menus 73

HEAT SETTINGS menus 75

DHW SETTINGS menus 78

CIRCULATOR EXERCISING and
FREEZE PROTECTION CIRCULATORS menus 80

DIAGNOSTIC menu 81

MAINTENANCE, DATE AND TIME menus 84

Startup — fill the system 85

Startup — final checks 87

Check-out/startup verification 92

Annual startup and general maintenance 93

Annual startup 94

Troubleshooting 100

Maintenance 108

Cleaning heat exchanger flue side, 70/110 110

Cleaning heat exchanger flue side, 155 113

Replacement parts 116

Dimensions 128

Ratings — WM97+ boilers 129

Ratings — Multiple WM97+ boilers 130

Installation and Service Certificate 131

WM97+ Gas Boiler Data Collection Sheet 132

DO NOT SERVICE THE

BOILER WITHOUT A WM97+

MAINTENANCE KIT AVAILABLE

The WM97+ maintenance kit includes components that

may have to be replaced when accessing or disassembling

parts of the boiler. Failure to replace damaged components

and to use only the parts specifically intended for the boiler

can result in severe personal injury, death or substantial

property damage. See Figure 119, page 117 for part number.

Summary of Contents for WM97+110

Page 1: ......

Page 2: ... WM97 control The WM97 control responds to signals from the room thermostats DHW aquastats if used boiler sensors boiler return boiler supply flue temperature and outdoor temperature if used see page 129 The control automatically adjusts blower speed and gas flow rate to match boiler output to space heating and or DHW heating demand The control provides for three heating zones DHW plus two space h...

Page 3: ...Part number 550 142 085 0712 3 WM97 gas fired water boiler Boiler Manual The WM97 70 110 Gas fired water boiler cont ...

Page 4: ...eturn 15 Gas connection pipe Manual gas valve is shipped loose Other NPT gas connection pipe and fittings including union shown must be supplied by the installer 16 WM97 control The WM97 control responds to signals from the room thermo stats DHW aquastats when used boiler sensors boiler return boiler supply flue temperature and outdoor temperature if used see page 129 The control automatically adj...

Page 5: ...Part number 550 142 085 0712 5 WM97 gas fired water boiler Boiler Manual The WM97 155 Gas fired water boiler continued ...

Page 6: ...nsate line 60 Gas piping 61 Field wiring 62 Wiring diagram schematic 65 Wiring diagram ladder 66 EXPRESS SETUP using default settings 67 WM97 control operation 69 ESSENTIAL settings 71 WM97 control settings 72 BOILER SETTINGS menus 73 HEAT SETTINGS menus 75 DHW SETTINGS menus 78 CIRCULATOR EXERCISING and FREEZE PROTECTION CIRCULATORS menus 80 DIAGNOSTIC menu 81 MAINTENANCE DATE AND TIME menus 84 S...

Page 7: ... materials Refer to the WARNING and instructions on page 94 BOILER OPERATION Do not block flow of combustion or ventilation air to boiler CARBON MONOXIDE DETECTOR A carbon monoxide detector that is wired on the same elec trical circuit as the boiler is strongly recommended SURGE PROTECTOR Provide surge protection in the boiler power supply This will reduce the possibility of damage to the boiler c...

Page 8: ... the boiler so it cannot be damaged by a moving vehicle Ensure that the installation complies with all applicable codes Prevent boiler water and condensate from freezing Provide air openings to room WM97 boiler alone in boiler room 1 No air ventilation openings into boiler room are needed if clearances around WM97 boiler are at least equal to the SERVICE clearances shown in Figure 1 page 9 2 For s...

Page 9: ...f boiler input B Left side clearance to combustibles 0 inches minimum C Top of boiler clearance to combustibles 10 5 inches minimum D Right side clearance to combustibles 0 inches minimum E Bottom of boiler clearance to combustibles 5 75 inches minimum must be 18 inches above floor for garage installations F Clearance in front of the boiler 0 5 inches but 24 inches minimum required for service G A...

Page 10: ...155 150 pounds Failure to comply with above and the procedure given below could result in severe personal injury death or substantial property damage 1 Stud spacing Bracket holes are spaced for studs on 16 inch centers For other stud spacing provide secure solid mounting surface on which to attach the boiler wall mounting bracket The mounting surface must not extend above the top of the boiler jac...

Page 11: ...he boiler but the boiler must ONLY be lifted by the bottom and rear of the sheet metal housing NOT by any pipe or plastic part 3 Obtain assistance to lift the boiler into position 4 Lift the boiler high enough that its rear bracket item 4 will be above the wall mount bracket item 2 5 Let the rear of the boiler slide against the lag screw heads as you lower the boiler into place 6 When the brackets...

Page 12: ...ed if exposed to pressure above 42 5 PSIG 1 CLOSE the boiler s primary secondary by pass valve item 30 page 3 and page 5 2 See Figure 7 page 13 for use with the following instructions 3 CLOSE boiler drain valve item 16 Connect a hose to fresh water supply and to the drain valve 4 Place a bucket under the ends of pipe nipples item 15 and item 17 to catch water drippage 5 CLOSE isolation valve 12 6 ...

Page 13: ...se shipped loose with boiler 8 1 NPT boiler water SUPPLY connection for DHW tank or CWH if used DO NOT use this connection for any application except DHW or CWH 9 1 NPT boiler water RETURN connection for DHW tank or CWH if used DO NOT use this connection for any application except DHW or CWH 10 1 NPT pipe cap shipped loose with boiler leave this in place if NOT connecting to DHW or CWH here remove...

Page 14: ...version Allow the boiler to cool if it has been operating Following conversion of an installed boiler follow all instructions in this manual to start up the boiler and verify operation of the boiler and all system components 1 Locate the propane orifice bushing from the propane conversion kit bag 2 Verify that the stamping on the orifice bushing is correct for the model size see Figure 8 3 If the ...

Page 15: ...i and reinstall the gas valve retention ring item 3 Figure 10 DO NOT ATTEMPT TO MEASURE VALVE OUTLET PRESSURE The valve could be damaged by manom eter fluid contamination Failure to comply could result in severe personal injury death or substantial property damage 10 After installation is complete attach the propane conversion label in conversion kit bag next to the boiler rating plate 11 Perform ...

Page 16: ...e is correct for the model size see Figure 11 3 If the jacket front door is not already removed remove it 4 See Figure 12 page 17 and Figure 13 page 17 for the following Figure 11 Propane gas orifice identification WM97 155 The jacket door must be in place during opera tion DO NOT operate the boiler with the jacket door removed except for inspection and testing as directed in this manual Support t...

Page 17: ...onversion label in conversion kit bag next to the boiler rating plate 14 Perform complete start up sequence beginning on page 85 including check for gas leaks and checking for proper operation 15 Reinstall jacket front panel LEGEND for Figure 12 amd Figure 13 1 Venturi leave venturi attached to blower 2 3 hex head screws 5 mm hex remove and retain 3 Honeywell gas valve 4 Air silencer leave connect...

Page 18: ...as a Pipe lengths in Figure 14 are equivalent length of straight pipe Convert pipe fittings to equivalent lengths using data from Figure 15 b Figure 14 is only for natural gas with specific gravity 0 60 with a pressure drop through the gas piping as listed in the table c For additional gas pipe sizing information refer toANSI Z223 1 or B149 1 or B149 2 for Canadian installations Natural gas supply...

Page 19: ...ther ap pliance When an existing boiler is replaced with an WM97 boiler the WM97 boiler CANNOT use the existing common vent The WM97 boiler requires its own vent and air piping as specified in this manual This may cause a problem for the appliances that remain on the old common vent because the vent may be too large The following test is intended to check for proper operation of the appliances rem...

Page 20: ...e 21 Size inches Materials Fig 18 page 21 70 2 PVC PVC DWV CPVC PP SS 2 PVC PVC DWV CPVC PP SS 2 PVC PVC DWV CPVC PP SS 2 PVC PVC DWV CPVC PP SS 2 PVC PVC DWV CPVC PP SS 3 PVC PVC DWV CPVC PP SS 3 PVC PVC DWV CPVC PP SS 3 PVC PVC DWV CPVC PP SS 3 PVC PVC DWV CPVC PP SS 3 PVC PVC DWV CPVC PP SS 110 2 CPVC PP or SS ONLY 2 CPVC PP or SS ONLY 2 CPVC PP or SS ONLY 2 CPVC PP or SS ONLY 2 CPVC PP or SS O...

Page 21: ...urchase separately see Figure 119 page 117 for part numbers Note 1 Weil McLain concentric vent kits are made from PVC pipe and fittings Note 2 IPEX PVC concentric terminations utilize PVC pipe fittings certified to ULC S636 If ULC S636 compliance is required use only IPEX System 636 pipe fittings and cement DO NOT mix piping from different pipe manufacturers unless using adapters specifically desi...

Page 22: ... print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BE LOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 thro...

Page 23: ... Boiler Manual Vent termination requirements Figure 19 The vent termination must be located to meet all requirements below also applies to vertical vent terminations For Canadian installations defer to the requirements of CSA B149 1 or B149 2 Installation Code ...

Page 24: ...e inch per 4 000 Btuh of all other appliances in the room OR ONE opening each at least 1 square inch per 3 000 Btuh of all other appliances in the room Unless specified otherwise by appliance manufacturer TWO openings each at least 1 square inch per 2 000 Btuh of all other appliances in the room OR ONE opening each at least 1 square inch per 3 000 Btuh of all other appliances in the room Unless sp...

Page 25: ...liant vent kit 3 The air inlet of a WM97 boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents For terminations of other appliances provide at least the clearance shown The installation must also comply with the manual for the other appliances Figure 21 Installation W M sidewall vent air plate Vent air pipes and ven...

Page 26: ...ng holes flue pipe and air pipe Level the template with a level For the Weil McLain plate the template must be level to ensure the flue and air pipe will be side to side as shown in Figure 23 Failure to comply could result in severe personal injury death or substantial property damage e Cut holes in the wall as shown in Figure 23 using the location marks made with the template For best results use...

Page 27: ...w all instructions in this manual DO NOT proceed with vent air installation until you have read page 19 through page 24 See notices at left Step 2 Install the boiler in a location that allows proper routing of all vent and air piping to the selected sidewall location Step 3 Make sure the selected sidewall termination location complies with Fig ure 19 page 23 Multiple boiler sidewall plates must al...

Page 28: ...ation of vent pipe when passing through floors or walls 5 Seal exterior openings thoroughly with exterior caulk Termination and fittings 1 Prepare the vent termination elbow and the air termination elbow by inserting bird screens See Figure 25 page 27 Bird screens must be purchased separately See the parts list at the end of this manual for part numbers 2 When completed the air termination couplin...

Page 29: ...ry death or substantial property damage 2 Place wall penetrations to obtain minimum clear ance as shown in Figure 29 page 30 for U S instal lations For Canadian installations provide clear ances required by CSA B149 1 or B149 2 Installation Code and a ULC S636 compliant vent kit 3 The air inlet of a WM97 boiler is part of a direct vent connection It is not classified as a forced air intake with re...

Page 30: ...e beginning vent and air piping from the boiler to the con centric termination mount and secure the concentric termination as shown in Figure 30 page 30 The vent and air piping must be securely supported and must not rest its weight on the boiler fittings Failure to properly support the vent and air piping could result in vent piping damage resulting in possible severe personal injury death or sub...

Page 31: ...connection It is not classified as a forced air intake with regard to spacing from adjacent boiler vents Figure 31 Separate pipes vertical termination Terminate vent and air pipes such that a AIR INTAKE IS AT LEAST 12 inches below vent outlet b AIR INTAKE IS NO FURTHER than 12 inches away center to center c AIR INTAKE IS AT LEAST 12 inches above roof or snow line d Vent and air terminations are fi...

Page 32: ...Follow all vent pipe manufacturer s instructions Termination and fittings 1 Prepare the vent termination elbow and the air termination elbow Figure 31 page 31 by inserting bird screens Bird screens must be purchased separately See the parts list at the end of this manual for part numbers 2 The air piping must terminate in a down turned 180 degree re turn bend as shown in Figure 31 page 31 Locate t...

Page 33: ... ULC S636 compliant vent kit Multiple vent air terminations 1 When terminating multipleWM97 boilers install the concentric vent air termination assemblies as described in this manual All vent outlets must terminate at the same height to avoid possibility of severe personal injury death or substantial property damage Figure 33 Installation sequence Concentric vertical Step 1 Read and follow all ins...

Page 34: ...st not rest its weight on the boiler fittings DO NOT drill or screw into either the vent pipe or air pipe Failure to properly support the vent and air piping could result in vent piping damage resulting in possible severe personal injury death or substantial property damage When inserting the partially assembled termination kit through the roof penetration wrap plastic or other protection over the...

Page 35: ...en in serted through the roof or sidewall and all supports have been installed Follow instructions to cover the end of the assembly with plastic before inserting through the roof penetration to prevent debris from blocking the air passages If necessary you can shorten the lengths of the inner and outer pipes for a shorter finished assembly But you must ensure the pipes butt correctly at both ends ...

Page 36: ...ions and also at the termi nation if using the W M termination plate Provide 2 or 3 PVC transitions at the termination if using a PVC concentric vent kit Install a locking collar at every joint For AL29 4C vent pipe applications comply with any additional requirements in the vent system manufac turer s instructions Provide a 3 PVC transition piece at the boiler vent connection Air piping must be P...

Page 37: ...0 boilers are equipped with an internal expansion tank factory charged to 12 PSIG 2 This expansion tank is suitable for most systems with total volume of 15 gallons or less See page 40 for suggestions for adding addi tional a supplementary expansion tank for higher volume systems 3 The maximum operating pressure of the internal expansion tank is 42 5 PSIG The internal expansion tank isolation valv...

Page 38: ...ternal circulators causing possible excess pressure on valves and system components Operate with the by pass closed using boiler circula tor for system flow ONLY where shown on application instructions in this manual DO NOT remove or relocate the boiler circulator DO NOT attempt to change the boiler internal piping Failure to comply with the above could result in severe personal injury death or su...

Page 39: ...alve from properly protecting the boiler resulting in possible severe personal injury death or substantial property damage DO NOT remove or relocate the boiler circulator DO NOT attempt to change the boiler internal piping Failure to comply with the above could result in severe personal injury death or substantial prop erty damage 1 The primary secondary by pass valve item 5 in the illus trations ...

Page 40: ...xpansion tank should be piped as in Figure 42 for dia phragm or bladder type tanks or Figure 43 for a closed type expan sion tank DO NOT install automatic air vents on closed type expan sion 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 DO NOT use a clo...

Page 41: ...the expansion tank Never locate this elsewhere in the system Diaphragm or bladder type tank Refer to Figure 44 for suggested piping when using a diaphragm or bladder type expansion tank Diaphragm or bladder type expansion tank Control fill pres sure with the tank air charge pressure Always check pressure and charge tank with tank removed from system to be sure reading is accurate Boiler relief val...

Page 42: ...oot MAXIMUM CIRCUIT LENGTH This is the maximum total length of any circuit measured along the piping beginning at the boiler along the main line through the heating branch and back to the boiler DO NOT use direct connection if any heating loop exceeds this value For systems other than finned tube or cast iron baseboard Use the CIRCULATOR HEADAVAILABLE to determine whether the boiler circulator can...

Page 43: ...ped to boiler supply connection see page 13 for information 4 Relief valve piping to drain see page 37 5 DHW circulator 6 Isolation valves 8 Supplementary expansion tank diaphragm type if used 9 Air separator 10 Flow check valve 11 Purge drain valves one drain valve is supplied loose with the boiler 12 Boiler circulator with inte gral flow check valve factory installed in boiler 13 Zone valves 14 ...

Page 44: ...to a Weil McLain Companion Water Heater ZONE VALVE zoning primary secondary Internal P S by pass valve OPEN WM97 70 or 110 only The boiler primary secondary by pass valve MUST be open to prevent excessive head caused by running the boiler circula tor and system circulator in series See Figure 49 1 This configuration is for WM97 70 or 110 zone valve systems that need more flow than the boiler s cir...

Page 45: ... Field wiring beginning on page 62 for instructions on wiring to zone valves 2 The boiler and zone valves can also be operated by a Weil McLain WMZV zone controller System piping continued Legend Figure 50 1 WM97 155 boiler 2 Indirect water heater when used for CWH installations refer to the Weil McLain CWH manual 3 Relief valve supplied with boiler field piped MUST be piped to boiler supply conne...

Page 46: ...l P S by pass valve OPEN WM97 70 or 110 only The boiler primary secondary by pass valve MUST be open to prevent excessive head caused by running the boiler circulator and zone circulators in series See Figure 51 1 OPEN the boiler internal primary secondary by pass valve 2 Install a separate circulator for each zone The boiler circulator cannot be used for a zone It must remain in the boiler as ins...

Page 47: ... valve OPEN WM97 155 only Theboilerprimary secondaryby passvalveMUSTbeopento prevent excessive head caused by running the boiler circulator and zone circulators in series See Figure 52 1 OPEN the boiler internal primary secondary by pass valve 2 Install a separate circulator for each zone The boiler circulator cannot be used for a zone It must remain in the boiler as installed at the factory Expan...

Page 48: ...de There is no need to regulate boiler return water temperature in radiant heating applications 2 Apply this configuration for typical radiant heating applications 3 Sizethesystempipingandcirculatorstoprovidetheflowandpressuredropneeded High limit in system piping 1 Add the recommended high limit control Figure 53 item 22 to help ensure supply water temperature will not exceed the maximum allowabl...

Page 49: ...ork well even in condensing mode There is no need to regulate boiler return water temperature in radiant heating applications 2 Apply this configuration for typical radiant heating applications 3 Size the system piping and circulators to provide the flow and pressure drop needed High limit in system piping 1 Add the recommended high limit control Figure 54 item 22 to help ensure supply water tempe...

Page 50: ... by pass valve OPEN WM97 70 or 110 only DO NOT use this piping if the boiler is connected to a CWH unit The CWH unit requires priority and would prevent priority operation of the system DHW unit The boiler internal primary secondary by pass valve MUST be open to prevent excessive head caused by running the boiler circulator and zone circulators in series See Figure 55 1 OPEN the boiler internal pr...

Page 51: ...ATOR zoning Internal P S by pass valve OPEN WM97 155 only DO NOT use this piping if the boiler is connected to a CWH unit The CWH unit requires priority and would prevent priority operation of the system DHW unit The boiler internal primary secondary by pass valve MUST be open to prevent excessive head caused by running the boiler circulator and zone circulators in series See Figure 56 1 OPEN the ...

Page 52: ...tors if a separate circulator is supplied for the chilled water loop Install a separate circulator for each zone The boiler circulator cannot be used for a zone It must remain in the boiler as installed at the factory If antifreeze is used in the system consider the effects of antifreeze on circulator sizing and DHW performance Some local codes may require double wall DHW heat exchanger design Use...

Page 53: ...ied for the chilled water loop Install a separate circulator for each zone The boiler circulator cannot be used for a zone It must remain in the boiler as installed at the factory If antifreeze is used in the system consider the effects of antifreeze on circulator sizing and DHW performance Some local codes may require double wall DHW heat exchanger design Use only the antifreeze listed by Weil Mc...

Page 54: ... and grade snow line as shown in Figure 60 b Provide minimum free area in duct adjusted for louver restric tion of 1 square inch per 2 000 Btuh total boiler input or see Figure 133 page 130 c If combustion air damper is used wire to boilers to prevent operation except after damper has opened ONLY air piping can be combined DO NOT use com bined vent piping Flue gas leakage and boiler compo nent dam...

Page 55: ...r steel pipe sized for the required flow rate 5 Install an isolation valve on the supply and return of each boiler as shown in the piping diagrams in this manual Some local codes may require the use of individual water level controls and limits on each boiler because isolation valves are installed 6 Install main system air eliminator and primary circulator in sup ply piping as shown in piping diag...

Page 56: ...kflow preventer as required by applicable codes 12 Isolation valve 13 Cold water supply 14 Supply water temperature control when used 15 Low water cutoff when used place above primary header 16 Water flow switch when used 17 Internal boiler circulator 18 System supply 19 System return 20 Boiler P T gauge relief valve and discharge piping installed per WM97 Boiler Manualore than 3 feet from boiler ...

Page 57: ... and Easy Fit Manifolds 18 System supply 19 System return 20 Boiler relief valve and discharge piping installed per WM97 Boiler Manual 21 Indirect fired storage water heaters Weil McLain PLUS Line shown Example is shown connected to one boiler of the system Preferably use the last boiler in the lead lag sequence and set its Priority to DHW Direct so it will switch to DHW firing and turn off its bo...

Page 58: ...ave its own circulator 22 DHW boiler water supply typical 23 DHW boiler water return typical 24 DHW boiler side circulators 25 DHW boiler side supply Easy Fit Manifold 26 DHW boiler side return Easy Fit Manifold 27 Flow check valves to prevent induced or gravity flow in heating system or DHW piping 28 Check valve to prevent heat migration in heating system 29 See water heater manual for DHW piping...

Page 59: ... temperatures must meet heating system requirements 2 Contact heat exchanger manufacturer for sizing heat exchanger 3 Heat exchanger shell side circuit requires its own expan sion tank as shown 4 Heating system circuit requires its own expansion tank as shown plus its own relief valve set to protect heating system and heat exchanger piping and components 5 When individual isolation valves are used...

Page 60: ...ping to drain or condensate pump Use materials approved by the authority having jurisdic tion In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 F441 or D2665 Cement and primer must comply with ASTM D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 2 Select a condensate pump if used that is approved for use with condensing boilers a...

Page 61: ...l injury death or substan tial property damage DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct out let pressure This setting is suitable for natural gas and propane Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve caus ing potential severe personal injury death or substantial property damage ...

Page 62: ...is of WM97 70 100 electrical entrances for WM97 155 are the same Line voltage wiring terminals See Figure 71 page 63 for wiring instructions The terminals include the 120 VAC power input and three 120 VAC outputs for circulators or other system devices WM97 wiring Terminals All field wiring is made to the two electrical con nection panels on top of the boiler Line voltage 120 VAC terminals are on ...

Page 63: ...nnection terminal block 1 Ground wires must be terminated with inch female spade terminals 2 Connect ground wires to the grounding block item B C Zone 1 output CIRC1 120 VAC DHW circuit if DHW used 1 The WM97 control provides 120 VAC outputs for up to three zones The WM97 control default setting is for three space heating zones The control settings must be changed to operate on DHW 2 Control optio...

Page 64: ...d from Zone 1 if domestic water priority is required 3 ALWAYS connect DHW aquastat to Zone 1 input if domestic prior ity is required This can be done if the DHW tank is piped to the DHW connections out the bottom of the WM97 or if the DHW tank is piped as a separate zone in the system J Zone 2 call for heat space heating 1 Use the Zone 2 input to a Connect the thermostat for a space heating zone b...

Page 65: ...Part number 550 142 085 0712 65 WM97 gas fired water boiler Boiler Manual Wiring diagram schematic Figure 73 WM97 schematic wiring diagram see Figure 74 page 66 for legend and notes ...

Page 66: ...Part number 550 142 085 0712 WM97 gas fired water boiler Boiler Manual 66 Wiring diagram ladder Figure 74 WM97 ladder wiring diagram see Figure 73 page 65 for schematic wiring diagram ...

Page 67: ...irculator when applying Figure 76 page 68 Failure to comply could cause system problems Figure 75 Using default control settings No DHW CIRCULATOR zoned systems primary secondary piping Legend and guidelines Figure 75 1 Wire the circulator outputs CIRC 1 CIRC 2 and CIRC 3 to the zone circulators See Figure 71 page 63 2 Wire the zone thermostats to the Zone 1 Zone 2 and Zone 3 inputs on the 24 VAC ...

Page 68: ... if used 3 Relief valve supplied with boiler field piped MUST be piped to boiler supply connection see page 13 for information 4 Relief valve piping to drain see page 37 5 DHW circulator 6 Isolation valves 7 System circulator 8 Supplementary expansion tank diaphragm type if used 9 Air separator 10 Flow check valves 11 Purge drain valves one drain valve is supplied loose with the boiler 12 Boiler c...

Page 69: ...rge and control starts cycle again After 5 failures the control waits 60 minutes then tries again If priority timer times out switch to next priority and start priority timer If demand satisfied go to postpurge Blower on Demand satisfied temperature reaches target temperature or limit setting Gas valve off Blower to ignition speed for postpurge Return to standby after purge Maintenance Display tur...

Page 70: ...eration continued Figure 79 WM97 control display screens and typical navigation CWH Installations See Companion Water Heater manual for additional screen information When the WM97 control detects the CWH temperature sensors it automati cally enables the CWH screens and CWH control operation ...

Page 71: ...hown on the dis play If the boiler model number shown does NOT match the boiler the selection MUST be changed to the correct model number Failure to comply could result in severe personal injury death or substantial property damage Step 8 Navigate to the BOILER SETTINGS HIGH ALTITUDE screen Step 9 If the boiler is installed at altitude above 5 500 feet the selection must be changed to YES If the b...

Page 72: ... SYSTEMS SETTINGS DHW SETTINGS menus 3 Adjust control settings as needed for the space heating and DHW systems supplied by the boiler 4 Wire the line voltage and low voltage connections as required 5 The CONTRACTOR MENU screen will show a BOILER SETTINGS see page 73 for details b SYSTEM SETTINGS see below c DIAGNOSTICS see page 81 d MAINTENANCE INFO see page 71 and page 84 e SET DATE AND TIME see ...

Page 73: ...Part number 550 142 085 0712 73 WM97 gas fired water boiler Boiler Manual Figure 81 BOILER SETTINGS menus see Figure 82 page 74 for setting values and descriptions BOILER SETTINGS menus ...

Page 74: ... is greater than the WWSD setting 2 When the boiler is kept off because the outside temperature is above WWSD the graphic display will show WWSD and the boiler will remain in standby until the outside temperature drops below WWSD temperature 3 WWSD does not apply to DHW systems 4 The outdoor sensor must be installed to use this function The outdoor sensor must be installed unless specifically exem...

Page 75: ...80 0 130 70 Cast iron baseboard CIB 180 0 120 70 Cast iron radiators CIR 180 0 120 70 Radiant slab on grade RSG 120 0 80 70 Radiant thin slab RTS 140 0 80 70 Radiant below floor staple up RFU 160 0 90 70 Radiant above floor sleeper system RAF 140 0 90 70 Custom CUS 190 0 70 70 Figure 83 HEAT SETTINGS menus see Figure 85 page 77 for setting values and descriptions See table below for system type ex...

Page 76: ...ally 180 F for finned tube baseboard on new installations MIN SUPPLY 1 MIN SUPPLY should equal the desired minimum supply water tem perature for the system 2 The factory default is 130 F This could be set as low as 70 F which would supply zero heat when outdoor temperature is 70 F because supply water temp would equal room temp 3 See examples in Figure 84 MAX OUTDOOR 1 MAX OUTDOOR means the outdoo...

Page 77: ...h Value Default Comment System Type Types Off Custom FTB Boiler Circulator Spd Selection Off High Med Select speed or select OFF to deactivate boiler during space heating call Max Supply F 60 190 180 Boiler enters manual reset lockout at 200 F Min Supply F 60 190 130 N A DHW does not use reset Max Outdoor F 50 100 70 N A DHW does not use reset Min Outdoor F 20 50 0 N A DHW does not use reset Modul...

Page 78: ...ure values can be changed if desired under TEMPERATURES CONTINUED ON NEXT PAGE BOILER CIRCULATOR SPEED Direct connected DHW bottom connections 1 The boiler circulator speed must be set to OFF for directly connected DHW applications 2 A separate DHW circulator must be supplied and wired to Circula tor 1 output DHW as a zone in the system 1 Boiler circulator as system circulator The boiler circulato...

Page 79: ...o DHW operation During DHW call for heat the space heating zone ouputs Zone 2 and Zone 3 are disabled This continues until the DHW call ends or the DHW MAX ON TIME has elapsed BOILER SUPPLY 1 The WM97 control will regulate boiler firing to provide outlet water at this temperature 2 For most DHW applications set this to 190 F A lower supply temperature can be used but will reduce the indirect water...

Page 80: ...ors chosen if the heat exchanger sensor detects a temperature less than 40 F The circulators turn off when the temperature rises above 45 F Menus Next screen Next screen Next screen DEFAULT Follow information at the bottom of each screen to navigate to next previous screen or enter save data SYSTEM SETTINGS CIRCULATOR EXERCISING CIRCULATOR 1 CIRCULATOR 2 CIRCULATOR 3 BOILER CIRC ON OFF ON OFF ON O...

Page 81: ...L OUTPUTS STATUS GAS VALVE BOILER CIRCULATOR CIRCULATOR 1 CIRCULATOR 2 CIRCULATOR 3 BLOWER SIGNAL ALARM ERRORS CONTROL FAULT IGNITION RETRIES MANUAL RESET CNT AUTO RESET CNT LOCKOUT HISTORY 1 LOCKOUT HISTORY HH MM AM MM DD YY STATUS MANUAL RESET AUTO RESET INPUTS OUTPUTS TEMPERATURES LIST OF LOCKOUTS LIST OF LOCKOUTS INPUT STATUS OUTPUT STATUS TEMPERATURES LOCKOUT HISTORY 2 LOCKOUT HISTORY 3 SAME ...

Page 82: ...trip Low Wtr Cutoff open closed data Low water cutoff device inside boiler jacket Blower Tach rpm data Feedback from blower sensor Flame Signal no units data Number indicating the presence and quality of the flame used to shutdown boiler Outputs Status Text data Current operating status of the boiler Prepurge Ignition Name of the system Type being satisfied post purge Warm Weather Shutdown Trouble...

Page 83: ...tus of the boiler at the time of the error Manual Reset yes or none data Choose this to view the details of manual reset lockouts Auto Reset yes or none data Choose this to view the details of auto reset lockouts Inputs menu menu Choose this to view the status of the Boiler Inputs at the time of the error Outputs menu menu Choose this to view the status of the Boiler Outputs at the time of the err...

Page 84: ... this to ignore the reminder and update only the Next Date Set Time and Date Year text 2011 Set year homeowner or contractor Month text 1 Set month homeowner or contractor Day text 1 Set day homeowner or contractor Hour text 12 Set hour homeowner or contractor Minute text 0 Set minute homeowner or contractor Figure 92 MAINTENANCE DATE AND TIME menus navigation see Figure 80 page 72 for access info...

Page 85: ...lose the boiler or system isolation valve between the purge valve and fill connection to the system 3 Close zone isolation valves 4 Open quick fill valve on cold water make up line 5 Open purge valve 6 One zone at a time open the isolation valves Allow water to run through the zone pushing out the air Run until no noticeable air flow is present Close the zone isolation valves Clean system to remov...

Page 86: ... and its internal piping 7 Close the quick fill water valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure 8 After the system has operated for a while eliminate any residual air by using the manual air vents located throughout the system 9 If purge valves are not installed in system open manual air vents in system one at...

Page 87: ...iring errors when re connecting them 2 Connect a voltmeter across each pair of incoming wires Close each thermostat zone valve and relay in the external circuits one at a time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring DO NOT connect the WM97 thermostat ter m...

Page 88: ...t flue gas spillage and carbon monoxide emissions which will result in severe personal injury or death Check gas piping 1 Check around the boiler and inside the boiler jacket for gas odor following the procedure of page 61 of this manual If you discover evidence of any gas leak shut down the boiler at once Find the leak source with bubble test and repair immediately Do not start boiler again until...

Page 89: ...50 142 085 0712 89 WM97 gas fired water boiler Boiler Manual Startup final checks continued Figure 95 Operating instructions WARNING Verify that the WM97 control is set for the correct boiler model before proceeding ...

Page 90: ...h the use of calibrated combustion test instruments Adjust the throttle screw only as needed to meet the combustion values given in Figure 97 1 Throttle screw adjustment is only necessary if specified elsewhere in this manual or if combustion tests indicate the need as explained under Check flame combustion with instruments page 88 2 Boiler behavior that might indicate a need to check combustion v...

Page 91: ... into low fire Check the combustion readings If results are acceptable at low fire verify high fire readings again Restore firing rate to AUTO DO NOT adjust throttle on low fire 7 Consult your local Weil McLain representative if acceptable results cannot be obtained for both high and low fire Figure 97 Acceptable combustion values measured values must be within the ranges given below Boiler model ...

Page 92: ... combustion verified per page 88 WM97 control operation for space heating and DHW if used verified per this manual Additional field installed controls tested as outlined by control manufacturers Boiler should be operating and should go off when controls are tested Verify controls cause automatic reset lockout or manual reset lockout as desired Additional field installed limit control s set to syst...

Page 93: ... Check automatic air vents if used Verify that domestic hot water is being supplied to fixtures at the correct temperature Every 6 months Check boiler piping gas and water Operate relief valve Service technician see page numbers indicated for details ANNUAL START UP See First year special inspection Address reported problems 95 Inspect boiler area 95 Inspect boiler interior door gaskets 95 Clean c...

Page 94: ...ts must be on hand when you perform the first year inspection in the event they must be replaced Failure to replace the items above when needed could result in severe personal injury death or substantial property damage 1 No later than 12 months after the boiler is installed perform a first year inspection of the boiler This should include the following in addition to routine annual start up proce...

Page 95: ...vide a reliable seal Replace any damaged gasket 3 Remove the venturi air inlet silencer and clean if necessary Reinstall silencer 4 Vacuum any sediment from the inside of the boiler and components Remove any obstructions Do not use solvents to clean any of the boiler components The components could be damaged resulting in unreliable or unsafe operation Clean condensate trap 1 See Figure 100 2 Disc...

Page 96: ...losed type tanks The air will escape from the system instead of returning to the tank Eventually the tank will waterlog and no longer control pressurization The boiler relief valve will weep frequently Diaphragm or bladder type welded gas tight with a rubber membrane to separate the tank pressurizing air and the water May be located at any point in the system but preferably located on the suction ...

Page 97: ...flame is unsatisfactory at either high fire or low fire check combustion values If combustion is properly adjusted turn off boiler and allow boiler to cool down Then remove burner andcleanitthoroughlyusingavacuumcleanerorcompressed air Do not use compressed air to clean burner if performed inside a building 3 To access the burner remove the heat exchanger cover plate following the procedure beginn...

Page 98: ...ance Minimum and maximum blower speeds can be adjusted within limits but chang ing speeds will affect AFUE ratings Check flue gas temperature 1 Set the boiler to high fire Then adjust the WM97 control display to view flue gas temperature and boiler return temperature 2 The flue gas temperature should be no more than 50 F higher than the boiler return temperature 3 If the flue temperature is higher...

Page 99: ...tive When manually operating the lever water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage Before operating lever check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal Otherwise severe personal injury or property damage may result If no water flows valve is ...

Page 100: ...at wire nuts and ground 2 Make sure all external limit controls are either installed and closed or temporarily jumpered for testing 3 Make sure that connectors toWM97 control are securely plugged in at module and originating control 4 Gas pressures Maximum 13 330 mm w c with no flow gas valve lockup pressure Minimum must be no less than the minimum values given on page 18 while operating on high f...

Page 101: ... cover and return control housing to normal position Replace screws item 4 and reconnect ignition cable at item 7 Checking temperature sensors 1 The boiler temperature sensors flue outdoor return water and supply water are all resistance type devices Figure 104 shows the correct value for the sensor at various temperatures For dual sensors the temperature difference between the sensors must be no ...

Page 102: ...97 control display and navigation instruc tions for all menus 2 Figure 108 shows the screen behavior during an automatic or manual reset condition The table below the display illustration lists manual reset condi tions and how to reset from them 3 Figure 109 page 103 lists conditions that will cause the control to display a constant red screen The boiler will automatically restart if the condition...

Page 103: ...was last cleared Select and press the enter key to reset this count Lockout History 1 Details of present or last recorded lockout Select and press the enter key for more details Lockout History 2 Details of boiler during the second oldest lockout still in memory Select and press the enter key for more details Lockout History 3 Details of boiler during the oldest lockout still in memory Select and ...

Page 104: ...se connections and proper pin alignment engagement on the WM97 control s plug P9 and the back of the display circuit board Check for continuity on the wire harness from the display to the WM97 control See repair parts section for proper replacement part Cycle power off and on using boiler power switch and check for operation Replace with new display module See repair parts section for proper repla...

Page 105: ... buildup Inspect vent system for abnormal wear or damage Contact Weil McLain Technical Support LOW WTR CUTOFF OPEN Occurs if internal low water cutoff contacts open Automatic reset occurs if contacts are open at least one second but less than 5 seconds Manual reset of WM97 control if contacts are open longer than 5 seconds Check for low water condition in system Repair system as necessary refer to...

Page 106: ... displayed TEMPERATURE SENSOR and follow procedure for loose connections FLAME FAULT Occurs if flame is detected when there should be no flame Reset using manual reset screen on display Burner may be operating too hot due to incorrect combustion Inspect flame and conduct combustion test Force boiler into hi fire Check flue gases with combustion analyzer and correct using the maintenance and startu...

Page 107: ...n be reset by performing manual reset on boiler Check condensate trap for blockage allowing condensate to accumulate inside heat exchanger Check ignition cable connection Fouled worn bent or faulty igniter Fouled igniters can be cleaned for additional use with steel wool Worn or badly fouled igniters should be replaced with the proper repair part Igniter rods should be parallel with a 3 5 mm 0 138...

Page 108: ...plac ing the circulator cartridge instead of replacing the entire circulator Replacing the circulator can be much more com plicated requiring more time to do 2 Purchase the circulator cartridge available through Weil McLain distributors Find the cartridge part number on the circulator label or in Figure 125 page 122 WM97 70 or 110 or Figure 127 page 124 WM97 155 3 Isolate and drain the boiler to a...

Page 109: ...nch flexible tube If the tube has been cut shorter attach a PVC coupling to the flexible tube with tape Then use a length of PVC pipe long enough to locate the funnel as directed 5 Insert a funnel into the open end of the flexible tube Wrap the funnel to tube joint with tape so it will be watertight 6 Lift the funnel up as shown in Figure 111 so it is from 6 to 10 inches above the bottom of the bo...

Page 110: ...y forward and out of the jacket j Remove the igniter by removing the two Phillips head igniter screws Set the igniter its gasket and screws aside Be careful when handling the igniter not to damage the igniter ceramic k Clean the igniter if necessary Discard and replace the igniter if it is damaged or cannot be cleaned Handle the cover plate venturi burner assembly carefully to avoid damage to the ...

Page 111: ...Part number 550 142 085 0712 111 WM97 gas fired water boiler Boiler Manual Figure 115 Accessing the burner or heat exchanger see Legend on next page Cleaning heat exchanger flue side 70 110 continued ...

Page 112: ... 12 over the burner Align the re fractory and press in place 5 Allow time for the adhesive to set before handling the as sembly 6 Reinstall the igniter assembly item 7 a The igniter gasket must be intact and in good condition Replace with a new gasket if necessary b Insert the igniter into the cover plate opening with the gasket in position c Reinstall the two Phillips head screws finger tight d U...

Page 113: ...maged in any way 6 Inspect the interior of the burner Brush and vacuum the interior if needed to remove lint or sediment Alternative cleaning methods blow air or nitrogen from the inside out clean with a water spray from inside the burner swirl the burner thoroughly in a bucket of mild liquid laundry deter gent water then rinse thoroughly 7 Inspect the burner exterior It must be in good condition ...

Page 114: ... with the five 6 mm nuts using a 10 mm wrench c Tighten the nuts gradually adjusting a little at a time Alternate and repeat until all are tightened evenly d Do not over tighten torques no more than 45 inch pounds 3 Reinstall the burner item 11 burner gasket item 12 and burner access cover seal item 13 on the heat exchanger cover plate item 6 a Insert and tighten the burner cover plate screws and ...

Page 115: ...Part number 550 142 085 0712 115 WM97 gas fired water boiler Boiler Manual Cleaning heat exchanger flue side 155 continued Figure 117 Accessing the burner or heat exchanger see Legend on next page ...

Page 116: ...ber of replacement part Results from us ing modified or other manufactured parts will not be covered by warranty and may damage boiler or impair operation THE BOILER CONTAINS CERAMIC FIBER MATERIALS The boiler contains ceramic fiber materials Use care when handling these materials per instructions on page 94 of this manual Failure to comply could result in severe personal injury REINSTALL JACKET D...

Page 117: ...pipe and PVC air pipe Includes W M sidewall vent air termination cap inside and outside cover plates and mounting hardware openings are sized for 3 PVC pipe requires field installed 3 x 2 adapter if using 2 vent air pipes 382 200 430 Item Description Part Number 170 Sidewall separate pipes vent air termination kits includes two cover plates Kit for 2 PVC vent and air pipes Kit for 3 PVC vent and a...

Page 118: ... 121 160 Door latch Latch and hardware 383 700 122 383 700 122 170 Gasket internal flue pipe to adapter Gasket fits inner diameter of boiler flue pipe 590 318 051 590 318 051 180 Flue pipe adapter Top flue adapter with internal gasket 560 907 719 560 907 719 190 Boiler flue pipe Internal flue pipe and gasket 560 907 720 560 907 720 200 Air inlet adapter Top air inlet adapter with internal gasket 5...

Page 119: ... 0712 119 WM97 gas fired water boiler Boiler Manual Replacement parts continued Figure 121 Jacket assembly WM97 70 110 155 see Figure 120 page 118 for part numbers Go to www weil mclain com to locate Weil McLain distributors ...

Page 120: ... for either boiler inlet or outlet water temperature 511 724 296 WM97 155 Figure 124 page 121 Item Name Part Number 100 Heat exchanger 319 100 001 105 Heat exchanger with condensate dish assembled includes items 100 160 170 and 180 383 700 198 110 Heat exchanger condensate dish cover plate burner igniter sight glass refractory water sensors gaskets silicone and hardware includes items 120 383 700 ...

Page 121: ... Manual Go to www weil mclain com to locate Weil McLain distributors Replacement parts continued Figure 123 WM97 70 110 heat exchanger assembly see Figure 122 page 120 for part numbers Figure 124 WM97 155 heat exchanger assembly see Figure 122 page 120 for part numbers ...

Page 122: ...3 210 WM97 110 boiler circulator cartridge Replacement cartridge for wet rotor 0015 circulator 511 405 143 220 Relief valve 30 PSIG relief valve shipped loose for field installation 383 500 095 230 Pressure temperature gauge Shipped loose for field installation 380 000 000 240 Air inlet silencer Silencer 383 700 155 250 Silencer o ring O ring 590 318 049 260 Blower Blower clip 383 700 157 265 Blow...

Page 123: ...0712 123 WM97 gas fired water boiler Boiler Manual Go to www weil mclain com to locate Weil McLain distributors Replacement parts continued Figure 126 Piping components for WM97 70 110 see Figure 125 page 122 for part numbers ...

Page 124: ...imary secondar by pass valve Ball valve compression fitting connection 511 246 400 190 Low water cut off Low water cut off 571 100 006 200 Gas valve Gas valve venturi gasket and hardware 383 700 196 220 Propane orifice if used In propane conversion kit see Figure 118 page 116 for number 230 Gas valve adapter block Threaded block o ring and screws 563 910 031 240 Gas flex line Gas pipe and hardware...

Page 125: ...5 0712 125 WM97 gas fired water boiler Boiler Manual Go to www weil mclain com to locate Weil McLain distributors Replacement parts continued Figure 128 Piping components for WM97 155 see Figure 125 page 122 for part numbers ...

Page 126: ...591 391 968 Wire harness WM97 155 591 391 992 160 Wire harness low voltage 22 pin connnector not shown Wire harness with terminal strips 591 391 967 165 Ignition cable not shown Ignition cable WM97 70 or 110 383 500 619 Ignition cable WM97 155 591 391 997 170 Control assembly Ignition control user display pump control wire harnesses plastic gasket label 383 700 139 180 Electrical enclosure Plastic...

Page 127: ... WM97 gas fired water boiler Boiler Manual Go to www weil mclain com to locate Weil McLain distributors Replacement parts continued Figure 130 Controls and electrical assemblies WM97 70 110 155 see Figure 129 page 126 for part numbers ...

Page 128: ...or field installation See page 61 for details and instructions 8 Drain valve shipped loose See Figure 6 page 12 for mounting details and instructions 9 Condensate drain connection also see item 14 below 10 Air connection 3 PVC 11 Relief valve shipped loose See page 37 for mounting details Relief valve mounts on supply pipe off of supply tee and street elbow as shown 12 Boiler drain line DHW boiler...

Page 129: ...nce should be made for unusual piping and pickup loads 4 WM97 boilers must be direct vented WM97 boilers require special venting consistent with Category IV boiler Use only the vent materials and methods specified in this manual WM97 70 or 110 vent air pipes can be either 2 or 3 WM97 155 vent air pipes must be 3 All vent and air pipe elbows must be sweep elbows NOT short radius elbows 5 Ratings sh...

Page 130: ...ce required Pounds per boiler Pounds per boiler Gallons per boiler GPM 20 F rise GPM 40 F rise Amps per boiler Note 4 Note 5 Note 3 70 136 140 2 8 6 5 3 3 2 or 3 15 0 110 136 140 2 8 10 0 5 0 2 or 3 15 0 155 162 150 3 4 14 3 7 2 3 15 0 Ratings Multiple WM97 boilers Notes 1 Based on standard test procedures outlined by DOE for individual boilers 2 Net I B R ratings are based on piping and pickup al...

Page 131: ...__OFF __ Manual Reset Temp F Max Supply F Boiler Supply F Boiler Supply F WWSD Temp F Min Supply F Adjust Outdoor F Max Outdoor F Circulator Exercising Min Outdoor F Circulator 1 On ___ Off ___ Modulate On Diff F Modulate On Diff F Modulate On Diff F Circulator 2 On ___ Off ___ Modulate Off Diff F Modulate Off Diff F Modulate Off Diff F Circulator 3 On ___ Off ___ Min On Time minutes Max On Time m...

Page 132: ...to reset Auto reset If yes description If yes description If yes description Temperatures Temperatures Temperatures Status Status Status Boiler out 1 Boiler out 1 Boiler out 1 Boiler out 2 Boiler out 2 Boiler out 2 Boiler in 1 Boiler in 1 Boiler in 1 Flue 1 Flue 1 Flue 1 Flue 2 Flue 2 Flue 2 Outdoor Outdoor Outdoor CWH Tank TOP CWH Tank TOP CWH Tank TOP CWH Tank BTM CWH Tank BTM CWH Tank BTM Input...

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Summary of Contents for WM97+110

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Summary of Contents for WM97+110

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