Weil-McLain WM97+ Aqua Logic Manual Download

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Part number 550-142-058/0811

WM97+

gas

fired

water

boiler

—

Boiler Manual

Display

Condition

Diagnostics

Corrective Action(s)

BLOWER FAULT

Blower unable to reach

required speed or does not

reach 0 RPM when turned off.

NOTICE: The blower will not

rotate without a low voltage

signal. Unplugging the low

voltage blower wire harness

will not allow or cause the

boiler to rotate.

Reset using manual reset screen

on display; control module will

check again after 1 hour and will

automatically restart if condition

is corrected

Check wire harness for loose connections and pin engagement at blower

connections, chassis mount connection through control housing, and

control module. Unplug connection at blower and at control module

and check continuity between ends. Blower is connected to both low

voltage and line voltage harness.

Check Diagnostics - Inputs screen with boiler in standby mode and

blower not running. If BLOWER SPEED is not 0 RPM then replace blower.

If blower does not rotate during ignition sequence check for 120V power

at blower connection. If 120Vac power at blower motor and it doesn't

start replace blower. Check power at control module. If 120Vac is not

present at control module when boiler is powered replace control

module. Refer to repair parts section.

IGNITION

FAULT

Boiler went through 5 ignition

attempts and never detected

flame

Automatically resets after 1 hour

or can 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 fine grit sand

paper or steel wool.

Worn or badly fouled igniters should be replaced with the proper repair

part.

Igniter rods should be parallel with a 3.5mm (0.138in) spark gap.

Dirty burner and/or heat exchanger will cause high back pressure and

poor ignition. Follow procedure in maintenance section of this manual

to clean burner and heat exchanger using flue cleaning tool and rinse

method.

Visual inspection of flueways will often will not be able to diagnose

condition.

Check combustion settings on high and low fire and adjust per setup

instructions if necessary.

Check incoming gas pressure with boiler off and at high fire. Adjust

within limits on rating label.

Verify correct boiler model is selected in control and high altitude is

selected for installations 5500ft above sea level.

Check ignition cable resistance. Should measure 1000 Ohms (+/- 50

Ohms)

Check for flue pipe and intake pipe restrictions or blockage

Check burner fasteners and gaskets

Check venturi gaskets and proper propane orifice bushing

Check condensate trap for blockage allowing condensate to accumulate

inside heat exchanger

Troubleshooting

(continued)

Figure 88 Troubleshooting suggestions for WM97+ boilers —

Fault displays, diagnostics and corrective actions

(cont.)

Summary of Contents for WM97+ Aqua Logic

Page 1: ...ng this manual and all other information shipped with the boiler before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Installation Startup Maintenance Parts Boiler Manual Part number 550 142 058 0811 Gas FiredWater Boilers ...

Page 2: ...responds to signals from the room thermostats DHW aquastats when used boiler sensors boiler return boiler supply flue temperature and outdoor temperature if used The control module 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 heating or three space heating DHW d...

Page 3: ...Part number 550 142 058 0811 3 WM97 gas fired water boiler Boiler Manual The WM97 Gas fired water boiler continued ...

Page 4: ...gram ladder 49 EXPRESS SETUP using default settings 50 Control module operation 52 ESSENTIAL settings 54 Control module settings 55 BOILER SETTINGS menus 56 HEAT SETTINGS menus 58 DHW SETTINGS menus 61 CIRCULATOR EXERCISING and FREEZE PROTECTION CIRCULATORS menus 63 DIAGNOSTIC menu 64 MAINTENANCE DATE AND TIME menus 67 Startup fill the system 68 Startup final checks 70 Check out startup verificati...

Page 5: ...e 76 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 control BOILER WATER The WM97 heat exchanger is made of ...

Page 6: ...149 2 for Canadian installations Locate or protect 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 when clearances around WM97 boiler are at least equal to the...

Page 7: ...NOTE If the installation does not provide the minimum clearances in Figure 1 then the enclosure MUST HAVE air openings located per Figure 2 above 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 inche...

Page 8: ...7 70 or WM97 110 140 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 t...

Page 9: ... Level the bracket and trace the outline of the screw slots with a pencil 7 Remove the mounting bracket and drill holes 1 4 diameter by 3 inches deep centered on the screw slot outlines For metal stud walls using 3 16 toggle bolts drill required clearance holes 8 Position the wal mount bracket and the upper spacer board on the wall Insert and loosely tighten the two lag screws or toggle bolts for ...

Page 10: ...ve from operating as needed resulting in possibility of severe personal injury death or substantial property damage 3 Install the pressure temperature gauge to the upper reducing tee Install fittings and valves required for hydrostatic testing 1 The following piping components supplied by installer are re quired for the hydrostatic test configuration a 2 1 NPT valves ball valve gate valve or other...

Page 11: ... cause injury 3 Remove hose after draining 4 Remove nipples and valves unless they will remain for use in the system piping 5 Remove plug and install relief valve as specified in the following WARNING Remove plug from relief valve street elbow Install the relief valve in the street See page 33 to install relief valve discharge piping Failure to install the boiler relief valve could result in sever...

Page 12: ...oiler and close the external manual gas shut off valve to isolate the boiler during conversion 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 t...

Page 13: ... and reinstall the gas valve retention ring item 3 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 complete st...

Page 14: ...1 are equivalent length of straight pipe Convert pipe fittings to equivalent lengths using data from Figure 12 b Figure 11 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 pressure 1 Pressure required...

Page 15: ...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 16: ...e 21 See page 23 See page 25 See page 27 See page 29 Size inches Materials Fig 15 page 17 Size inches Materials Fig 15 page 17 Size inches Materials Fig 15 page 17 Size inches Materials Fig 15 page 17 Size inches Materials Fig 15 page 17 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...

Page 17: ... 95 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 fit tings certified to ULC S636 Where ULC S636 compliance is required use only IPEX System 636 pipe fittings and cement DO NOT mix piping from different pipe manufactur ers unless using adapters specifically designed for the purpose by the manufa...

Page 18: ... 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 19: ... Boiler Manual Vent termination requirements Figure 16 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 20: ... 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 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 app...

Page 21: ... lation 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 regard to spacing from adjacent boiler vents For terminations of other appliances provide at least the clearance shown Fig ure 19 The installation must also comply with the manual for the other appliances Figure 18 INSTALLATION W M sid...

Page 22: ...th 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 19 Failure to comply could result in severe personal injury death or substantial property damage e Cut holes in the wall as shown in Figure 20 using the location marks made with the template For best results use a small diameter long drill bit to drill centering h...

Page 23: ... in this manual DO NOT proceed with vent air installation until you have read page 15 through page 20 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 16 page 19 Multiple boiler sidewall plates must also comply with Fig...

Page 24: ...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 22 page 23 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 25: ...ial property damage 2 Place wall penetrations to obtain minimum clear ance as shown in Figure 26 page 26 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 regard to spacing from...

Page 26: ...beginning vent and air piping from the boiler to the con centric termination mount and secure the concentric termination as shown in Figure 27 page 26 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 subst...

Page 27: ...149 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 regard to spacing from adjacent boiler vents Figure 28 Separate pipes vertical termination Step 1 Read and follow all instructions in this manual DO NOT proceed with vent air installation until you have read page 15 through ...

Page 28: ...Follow all vent pipe manufacturer s instructions Termination and fittings 1 Prepare the vent termination elbow and the air termination elbow Figure 28 page 27 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 28 page 27 Locate t...

Page 29: ...nt 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 30 INSTALLATION SEQUENCE Concentric vertical Step 1 Read and follow all instructions in this...

Page 30: ... 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 e...

Page 31: ...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 32: ...er vent and air connections and also at the termina tion when using the W M termination plate Provide 2 or 3 PVC transitions at the termination if using a PVC concentric vent kit 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 PVC or CPVC Conn...

Page 33: ...1 The boiler is 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 35 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 va...

Page 34: ...ate in series with external 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 person...

Page 35: ...lica tion guidelines Existing expansion tanks 1 An existing expansion tank should be piped as in Figure 37 for dia phragm or bladder type tanks or Figure 38 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 r...

Page 36: ...from the maximum flow for any circuit BTUH GPM x 500 x 20 F MAXIMUM FEET BASEBOARD This is determined from the maximum load assuming baseboard output of 600 Btuh per foot 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 he...

Page 37: ...ped MUST be piped to boiler supply connec tion see page 10 for informa tion 4 Relief valve piping to drain see page 33 5 DHW circulator 6 Isolation valves 8 Supplementary expansion tank diaphragm type when 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 ...

Page 38: ...ula tor internal flow check valve prevents circulation in the boiler loop during DHW heating 5 Controlling the circulators a The control module can control up to three zones DHW 2 space heating or 3 space heating Refer to Field wiring be ginning on page 45 for instructions on wiring to circulators b For more than 3 zones use a Weil McLain WMZV zone con troller See suggested wiring in this manual I...

Page 39: ...his occurs The boiler circula tor internal flow check valve prevents circulation in the boiler loop during DHW heating 5 Controlling the circulators a The control module can control up to three zones DHW 2 space heating or 3 space heating Refer to Field wiring be ginning on page 45 for instructions on wiring to circulators b For more than 3 zones including DHW if used use a Weil McLain WMCR zone c...

Page 40: ...emperature in radiant heating applications 2 Connect boiler to system as shown in Figure 44 for typical radiant heating applications The primary secondary piping shown ensures the boiler loop will have sufficient flow Size the system piping and circulator to provide the flow and pressure drop needed for the radiant system 3 Adding the recommended high limit control Figure 44 item 22 can help ensur...

Page 41: ...r must be set to ON during all zone op erations 5 Controlling the circulators a The control module can control up to three zones DHW 2 space heating Refer to Field wiring beginning on page 45 for instructions on wiring to circulators b For more than 3 zones including DHW use a Weil McLain WMCR zone controller See suggested wiring in this manual Install water piping continued Legend Figure 45 1 WM9...

Page 42: ...control module can control up to three zones DHW 2 space heating or 3 space heating Refer to Field wiring be ginning on page 45 for instructions on wiring to circulators b For more than 3 zones including DHW if used use a Weil McLain WMCR zone controller Figure 46 Chilled water system plus optional DHW piping Install water piping continued Legend Figure 46 1 WM97 boiler 2 Indirect water heater whe...

Page 43: ... the flexible drain line Run the drain tubing or piping to a floor drain or condensate pump The flexible drain line will fit in a PVC coupling Run minimum PVC for the piping 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 D25...

Page 44: ... not check for gas leaks with an open flame use bubble test Failure to use bubble test or check for gas leaks can cause severe personal 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 val...

Page 45: ...adder wiring diagrams Line voltage wiring terminals See Figure 51 page 46 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 the left Low voltage 24 VAC terminals are o...

Page 46: ...e surges B Ground wire connection 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 120 VAC DHW circuit if DHW used 1 The control module provides 120 VAC outputs for up to three zones The control module default setting is for three space heating zones The control settings must be changed to operate...

Page 47: ...ority is required This can be done when the DHW tank is piped to the DHW connections out the bottom of the WM97 or when the DHW tank is piped as a separate zone in the system 4 Zone valve applications see WARNING at right 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 Connect end switch wire s must be ISOLATED contacts to start bo...

Page 48: ...Part number 550 142 058 0811 WM97 gas fired water boiler Boiler Manual 48 Wiring diagram schematic Figure 53 WM97 schematic wiring diagram see Figure 54 page 49 for legend and notes ...

Page 49: ...Part number 550 142 058 0811 49 WM97 gas fired water boiler Boiler Manual Wiring diagram ladder Figure 54 WM97 ladder wiring diagram see Figure 53 page 48 for schematic wiring diagram ...

Page 50: ...itations given on page 36 and page 37 Install a system circulator when applying Figure 56 page 51 Failure to comply could cause system problems Figure 55 Using default control settings No DHW CIRCULATOR zoned systems primary secondary piping Legend and guidelines Figure 55 1 Wire the circulator outputs Zone 1 Zone 2 and Zone 3 to the zone circulators See Figure 51 page 46 2 Wire the zone thermosta...

Page 51: ...ped to boiler supply connec tion see page 10 for informa tion 4 Relief valve piping to drain see page 33 5 DHW circulator 6 Isolation valves 7 System circulator 8 Supplementaryexpansiontank diaphragm type when used 9 Air separator 10 Flow check valves 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 bo...

Page 52: ...postpurge 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 Displ...

Page 53: ...Part number 550 142 058 0811 53 WM97 gas fired water boiler Boiler Manual Control module operation continued Figure 59 Control module display screens and typical navigation see Figure 63 page 58 ...

Page 54: ...t 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 boiler is installed at altitude above 5 500 feet the high altitude selection MUST be changed to YES Failure to comply could result in severe personal injury death or su...

Page 55: ...ified to allow operation of a DHW circuit The circuit must be wired ONLY to Zone 1 DHW settings are done in the 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 56 for details b SYSTEM S...

Page 56: ...Part number 550 142 058 0811 WM97 gas fired water boiler Boiler Manual 56 Figure 61 BOILER SETTINGS menus see Figure 62 page 57 for setting values and descriptions BOILER SETTINGS menus ...

Page 57: ...iler will not be allowed to fire if the outside temperature 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 AD...

Page 58: ...Cast iron baseboard IRN BASE 180 0 120 70 Cast iron radiators RADIATOR 180 0 120 70 Radiant slab on grade RAD SLAB 120 0 80 70 Radiant thin slab RAD SLAB 140 0 80 70 Radiant below floor staple up RADFLOOR 160 0 90 70 Radiant above floor sleeper system RADFLOOR 140 0 90 70 Custom CUSTOM 190 0 70 70 Figure 63 HEAT SETTINGS menus see Figure 62 page 57 for setting values and descriptions See table bel...

Page 59: ...ed 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 64 MAX OUTDOOR 1 MAX OUTDOOR means the outdoor temperature at wh...

Page 60: ...oiler 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 Modulate On Diff F 2 10 5 Boiler turns on if temperature drops ...

Page 61: ...l module 2 The temperature presets are chosen based on normal best setting for DHW systems The tem perature 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 Circul...

Page 62: ... gives priority to 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 control module 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...

Page 63: ...tors 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 ...

Page 64: ...RPM FLAME SIGNAL OUTPUTS STATUS GAS VALVE BOILER CIRCULATOR V 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 LOCKOU...

Page 65: ...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 Gas Valve on off data Control s gas valve circuit status Boiler circulator volts data Control s variable voltage sent to control the boiler circulator speed 0V OFF 10V 100 Hig...

Page 66: ...ckouts 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 error Temperatures menu menu Choose this to view the Boiler Temperatures at the time of the error Software Versions Display fo...

Page 67: ... 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 72 MAINTENANCE DATE AND TIME menus navigation see Figure 60 page 55 for access info...

Page 68: ... Close 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 rem...

Page 69: ...ernal 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 a time begi...

Page 70: ...cur under any condition check and correct the external wiring DO NOT connect the WM97 thermostat ter minals to 3 wire zone valves This could cause control module damage 5 Once the external thermostat circuit wiring is checked and corrected if necessary reconnect the external thermostat circuit wires Inspect fill condensate system Inspect check condensate lines and fittings 1 Inspect the condensate...

Page 71: ...evere personal injury death or substantial property damage Propane boilers verify conversion 1 Verify propane orifice bushing has been installed See page 12 DO NOT attempt to mea sure gas valve outlet pressure DO NOT adjust or attempt to measure gas valve outlet pressure The gas valve is factory set for the correct outlet pressure This setting is suitable for natural gas and pro pane requiring no ...

Page 72: ...0 142 058 0811 WM97 gas fired water boiler Boiler Manual 72 Startup final checks continued Figure 75 Operating instructions WARNING Verify that the control module is set for the correct boiler model before proceeding ...

Page 73: ... is in adjustment include difficulty igniting poor flame stability at low fire combus tion noise or high carbon monoxide values 3 Combustion readings must be taken at both high fire and low fire DO NOT attempt an adjustment of the throttle screw at low fire Just check the combustion values 4 Use the control module display to navigate to Manual test mode see Figure 69 page 64 Force the firing rate ...

Page 74: ...nufacturers 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 system temperature requirements Balancing valves and controls adjusted to provide design temperature to system Flow adjusted balanced for each zone of multiple zones systems Thermostat he...

Page 75: ...ning with Startup fill the system page 68 Check low water cutoff service light Flame inspection stable uniform Flame signal see page 79 Clean heat exchanger if flue temp is more than 50 F above return water temp Inspect jacket front door gaskets replace if necessary Additional if combustion or performance indicate need Clean heat exchanger Remove and clean burner using compressed air only Vacuum t...

Page 76: ...n Replacement parts sec tion of this manual These parts 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 f...

Page 77: ...ovide 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 79 2 Disc...

Page 78: ...temswithclosed 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...

Page 79: ... fire check com bustion values If combustion is properly adjusted turn off boiler and allow boiler to cool down Then remove burner and clean it thoroughly using a vacuum cleaner or compressed 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 fol lowing the procedure beginning on page 91 4 When replacing the bur...

Page 80: ...listed in the previous steps contact the factory for technical assistance Minimum and maximum blower speeds can be adjusted within limits but changing speeds will affect AFUE rat ings Check flue gas temperature 1 Set the boiler to high fire Then adjust the control module display to view flue gas temperature and boiler return temperature 2 The flue gas temperature should be no more than 50 F higher...

Page 81: ...r 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 may result If no water flows valve is inoperative Shut down boiler until a new relief valve has been...

Page 82: ...or 24VAC between thermostat 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 to control module 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 ...

Page 83: ...th or substantial property damage 5 Reinstall control housing 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 83 shows the correct value for the sensor at various temperatures 2 Use the resis...

Page 84: ...e control module display and navigation instructions for all menus 2 Figure 87 shows the screen behavior during an automatic or manual reset condition The table below the display illustra tionlistsmanualresetconditionsandhowtoresetfromthem 3 Figure 88 page 85 lists conditions that will cause the control to display a constant red screen The boiler will automatically restart if the condition self co...

Page 85: ... 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 86: ...l If fuse blows again recheck wiring per diagram Nothing is shown on display screen but boiler is operating Occurs when the communication is lost from the control module to the display Check for loose connections and proper pin alignment engagement on the control module s plug P9 and the back of the display circuit board Check for continuity on the wire harness from the display to the control modu...

Page 87: ...control housing and the control module Unplug connection at sensor and at control module and check continuity between ends If problem persists after checking items above replace control module Refer to repair parts section for kit number Occurs when dual temperature sensors values have spread by more that 10ºF if the burner is on Automatically resets when sensors are within 10ºF Follow procedure f...

Page 88: ... heating zones Refer to the control module Setup section to configure these properly for the system Verify water pipe is installed correctly per instructions in this manual Verify proper circulator sizing for boiler size and system requirements See message displayed TEMPERATURE SENSOR and follow procedure for loose connections FLAME FAULT Occurs when flame is detected when there should be no flame...

Page 89: ...lame Automatically resets after 1 hour or can 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 fine grit sand paper or steel wool Worn or badly fouled igniters should be replaced with the pr...

Page 90: ...stead of replacing the entire circulator Re placing the circulator can be much more complicated requiring more time to do 2 Purchasethecirculatorcartridge item190 210 Figure99 page101 for the boiler circulator See the correct cartridge part number in Figure 98 page 100 and on circulator label Cartridges are available from Weil McLain and their distributors 3 Isolate and drain the boiler Disconnect...

Page 91: ... removing any pieces of refrac tory than may have dropped into the exchanger DO NOT use any solvent when cleaning the ex changer 5 If the vacuum cleaner is unable to clean completely wash the heating surfaces with clean warm water a Place a bucket under the boiler condensate drain con nection Cleaning the heat exchanger FLUE SIDE or accessing the burner when required The boiler contains ceramic fi...

Page 92: ...Part number 550 142 058 0811 WM97 gas fired water boiler Boiler Manual 92 Figure 90 Accessing the burner or heat exchanger see Legend on next page Maintenance continued ...

Page 93: ...alve retainer clip item 4 into position to secure the gas valve 13 Reinstall the condensate trap on the boiler condensate drain connection See Figure 47 page 43 for reference Perform a complete start up procedure when put ting the boiler back into service See page 68 and all instructions for start up and verification Include a soap suds leak test on all interior and exterior gas piping after start...

Page 94: ...rvicing The boiler front door must be se curely fastened to the boiler to prevent boiler from drawing air from inside the boiler room This is particularly important if the boiler is located in the same room as other appliances Failure to keep the door securely fastened could result in severe personal injury or death BEFORE SERVICING or MAKING CONNECTIONS ALWAYS TURN POWER OFF TO THE BOILER TO PREV...

Page 95: ...polypropylene pipe 3 polypropylene pipe 24PPS VK 35PPS VK 170 M G Simpson Duravent PolyPro SIDEWALL separate air and vent pipes 2 polypropylene pipe 3 polypropylene pipe 2PPS HTP 3PPS HTP Item Description Part Number VENT AIR TERMINATION PARTS AND KITS available from Weil McLain 180 Weil McLain sidewall vent air cap termination kit for PVC vent and air pipes Includes W M sidewall vent air terminat...

Page 96: ...0 150 Gasket heat exchanger to bottom panel Gasket condensate trap to bottom panel 383 700 121 160 Door latch Latch and hardware 383 700 122 170 Gasket internal flue pipe to adapter Gasket fits inner diameter of boiler flue pipe 590 318 051 180 Flue pipe adapter Top flue adapter with internal gasket 560 907 719 190 Boiler flue pipe Internal flue pipe and gasket 560 907 720 200 Air inlet adapter To...

Page 97: ...50 142 058 0811 97 WM97 gas fired water boiler Boiler Manual Replacement parts continued Figure 95 Jacket assembly see Figure 94 page 96 for part numbers Go to www weil mclain com to locate Weil McLain distributors ...

Page 98: ...nger to condensate dish 383 700 103 140 Condensate dish to flue pipe gasket Gasket to seal condensate dish to internal flue pipe 383 700 104 150 Refractory insulation Refractory silicone 383 700 105 160 Heat exchanger cover plate Cover plate refractory silicone and gaskets 383 700 108 170 Cover plate gasket Gasket heat exchanger to cover plate 383 700 109 180 Sight glass kit Bracket glass gaskets ...

Page 99: ...42 058 0811 99 WM97 gas fired water boiler Boiler Manual Go to www weil mclain com to locate Weil McLain distributors Replacement parts continued Figure 97 Heat exchanger assembly see Figure 96 page 98 for part numbers ...

Page 100: ...97 110 boiler circulator cartridge Replacement cartridge for wet rotor 0015 circulator 511 405 143 220 Relief valve 30 Psi 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 Blower retain...

Page 101: ... 142 058 0811 101 WM97 gas fired water boiler Boiler Manual Go to www weil mclain com to locate Weil McLain distributors Replacement parts continued Figure 99 Piping assemblies see Figure 98 page 100 for part numbers ...

Page 102: ... pin connector not shown Wire harness 591 391 968 160 Wire harness low voltage 22 pin connnector not shown Wire harness with terminal strips 591 391 967 165 Ignition cable not shown Ignition cable 383 500 619 170 Control assembly Ignition control user display pump control wire harnesses plastic gasket label 383 700 139 180 Electrical enclosure Plastic electrical enclosure 383 700 140 190 Line volt...

Page 103: ...0811 103 WM97 gas fired water boiler Boiler Manual Go to www weil mclain com to locate Weil McLain distributors Replacement parts continued Figure 101 Controls and electrical assemblies see Figure 100 page 102 for part numbers ...

Page 104: ...rain connection also see item 14 below 10 Air connection 3 PVC 11 Relief valve shipped loose See page 33 for mounting details Relief valve mounts on supply pipe off of supply tee and street elbow as shown 12 Boiler drain line DHW boiler water return line if DHW tank is connected directly to the boiler See Figure 7 page 11 for details and in structions for usage 13 DHW boiler water supply line if D...

Page 105: ... Capacity and AFUE are certified by AHRI AFUE is also know as Annual Fuel Utilization Efficiency or Seasonal Efficiency 3 Net I B R ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup Ratings are based on a piping and pickup allowance of 1 15 An additional allowance should be made for unusua...

Page 106: ...TA BOILER Settings HEAT Settings DHW Settings Boiler Model WM97 ________ System Type DHW OFF ___ ON ___ High Altitude Yes ____ NO ____ Boiler Circ Speed HIGH __ LOW __ MED __OFF __ Boiler Circ Speed HIGH __ LOW __ MED __OFF __ Manual Reset Temp F Max 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 ___ Modu...

Page 107: ...escription If yes description Auto reset Auto 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 Inputs Inputs Inputs Status Status Statu...

Page 108: ...108 WM97 gas fired water boiler Boiler Manual ...

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