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Weil-McLain WM97+100 Manual

Series 2 gas-fired water boilers
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Boiler Manual
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Matching High Performance
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Companion Water Heater
(Unit sold separately)
This manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including 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.
Part number 550-142-204/0117

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Summary of Contents for Weil-McLain WM97+100

  • Page 1 Boiler Manual Now available Matching High Performance Š Companion Water Heater (Unit sold separately) This manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including 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.

  • Page 2: Table Of Contents

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Contents DO NOT SERVICE THE The WM97+ 70 & 110 Gas-fired water boilers ..3 BOILER WITHOUT A WM97+ MAINTENANCE KIT AVAILABLE The WM97+110 Gas-fired water boiler ... . 5 The WM97+155 Gas-fired water boiler .

  • Page 3: The Wm97+ 70 & 110 Gas-Fired Water Boilers

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER The WM97+ 70 & 110 Gas-fired water boilers two space-heating or three space heating). DHW direct-connected to the bottom piping connections can be set for domestic priority. The WM97+ control is mounted in a plastic housing assembly The advanced blower design and air inlet silencer on WM97+ boilers that can rotate forward for rear access to the control boards or for result in very quiet operation.

  • Page 4: Gas - Fired Water Boiler

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER The WM97+70 Gas-fired water boiler – 4 – Part number 550-142-204/0117...

  • Page 5: The Wm97+110 Gas-Fired Water Boiler

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER The WM97+110 Gas-fired water boiler – 5 – Part number 550-142-204/0117...

  • Page 6: The Wm97+155 Gas-Fired Water Boiler

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER The WM97+155 Gas-fired water boiler direct-connected to the bottom piping connections can be set for domestic priority. The advanced blower design and air inlet silencer on WM97+ boilers The WM97+ control is mounted in a plastic housing assembly that result in very quiet operation.
  • Page 7 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER The WM97+155 Gas-fired water boiler (continued) – 7 – Part number 550-142-204/0117...

  • Page 8: Please Read Before Proceeding

    Weil-McLain boiler. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

  • Page 9: Boiler Location

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Boiler location Installations must comply with: Locate or protect the boiler so it cannot be damaged by Local, state, provincial, and national codes, laws, regulations a moving vehicle. and ordinances. Ensure that the installation complies with all applicable National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edi- codes.
  • Page 10 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Boiler location (continued) Provide clearances for service Provide clearances from combustible access — RECOMMENDED materials — REQUIRED 1. See Figure 1 for recommended service clearances. 1. See Figure 2 for REQUIRED minimum clearances. ALL installa- tion must provide at least these minimums.

  • Page 11: Wall-Mounting The Boiler

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Wall-mounting the boiler Remove boiler from crate Boiler shipping container (WM97+70 shown) . Use caution not to drop the boiler or cause bodily injury while lifting and handling. Verify that the boiler is securely attached to prevent possibility of boiler falling after installation.
  • Page 12 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Wall-mounting the boiler (continued) Install the wall-mount bracket and Place boiler on wall-mount bracket spacer boards (by installer) 1. See Figure 4, page 11. 2. Locate the studs — must be on 16-inch centers. See previous page instructions if studs are not on 16-inch centers.

  • Page 13: Boiler Hydrostatic Test

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Boiler hydrostatic test Fill and pressure test . This is the maximum allowable relief valve setting for the WM97+ boiler. Failure before hydrostatic testing. The tank will be to comply could prevent the relief valve damaged if exposed to pressure above 42.5 PSIG.
  • Page 14 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Boiler hydrostatic test (continued) Install pipe fittings for relief Install piping components required for hydrostatic test (WM97+70/110 shown) valve and pressure/temperature (see legend below) gauge — (see legend at right) 1 Boiler supply (outlet) connection, (male, 1” NPT on 70/110, 1¼” NPT on 155). 2 Boiler return connection, (male, 1”...

  • Page 15: Converting Boiler To Propane — Wm97+70

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Converting boiler to propane — WM97+70 Propane gas orifice bushing identification Prepare boiler for propane — WM97+70 (may be stamped WM97+70 only (if required) Propane operation — For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding.
  • Page 16 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Converting boiler to propane — WM97+70 (cont.) Installing the propane gas orifice bushing (some details omitted for clarity) 7. See Figure 10. Insert the propane gas orifice bushing (item 4) for Figure 10 into the gas valve outlet as shown.

  • Page 17: Converting Boiler To Propane — Wm97+110

    WM97+ Series 2 — Boiler Manual fired water boiler Converting boiler to propane — WM97+110 Figure 11 Propane gas orifice identification Prepare boiler for propane — WM97+ 110 (may be stamped 3.7 only) WM97+ 110 only (if required) Propane operation ALL WM97+ boilers must be converted for propane operation Converting an existing natural gas-fired...
  • Page 18 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Converting boiler to propane — WM97+110 (cont.) WM97+ 110 - Installing the propane gas orifice (some details omitted for clarity) for Figure 13 Gas valve Venturi Bolts (2) for attaching gas valve to venturi Blower Air silencer bracket clip Propane orifice with boot...

  • Page 19: Converting Boiler To Propane — Wm97+155

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Converting boiler to propane — WM97+155 Prepare boiler for propane — WM97+155 only When re-attaching the gas valve, ensure the gas (when required) valve grommet (item 8, Figure 16, page 20) is in place and in good condition.
  • Page 20 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Converting boiler to propane — WM97+155 (cont.) Installing the propane gas orifice bushing (some details omitted for clarity) Gas valve and vent for Figure 15 and Figure 16 Venturi (leave venturi attached to blower). Three (3) hex-head screws, 5 mm hex (remove and retain).

  • Page 21: Natural Gas

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Gas piping — sizing gas lines Boiler gas connection is ½” NPT. Size gas lines large Pipe capacity for 0.60 specific gravity enough to provide gas to all connected appliances. natural gas; pipe length is in equivalent feet.

  • Page 22: Venting/Air Piping — General

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Venting/air piping — general Any improper operation of the common venting system should be cor- rected so the installation conforms with the National Fuel Gas Code, ANSI Install air inlet piping for the WM97+ Z223.1/NFPA 54, and/or the Natural Gas and Propane Installation Code, boiler as described in this manual.

  • Page 23: Note 1

    Maximum vent lengths apply for either 2” or 3” vent and air pipe. If using 2” pipe, provide 3”x 2” tappered reducers at boiler connections and at Weil-McLain vent/air cap or at concentric terminations. Boilers will derate as vent/air pipe length increases — see rating data on Figure 144, page 141 for derate amounts.
  • Page 24 Purchase bird screens separately from Weil-McLain or vent kit supplier if not included. [Note — bird screening is integral to the 3” PVC Weil-McLain sidewall vent cap, supplied standard with all WM97+ boilers. No additional screening is required.] –...

  • Page 25: Commonwealth Of Massachusetts Installations

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Commonwealth of Massachusetts installations Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts, the boiler must be installed by a licensed plumber or gas fitter. Read and comply with the instructions below. (a) For all sidewall horizontally-vented gas-fueled equipment .

  • Page 26: Vent Termination Requirements

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Vent termination requirements The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

  • Page 27: Boiler Room Air Openings

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Boiler room air openings Combustion and ventilation air openings for Direct Vent installations, also follow the National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1 or applicable provisions of the local building codes.
  • Page 28 Prepare the sidewall penetrations and secure the sidewall plates as this manual. instructed in this section. See “Install Weil-McLain vent/air cap” on page 29 . All vent pipes and air inlets must ter-...
  • Page 29 Use the template to mark the locations for the four mounting holes, flue pipe and air pipe. Level the template with a level. For the Weil-McLain plate, the template must be level to Hole preparation in wall — INSIDE VIEW ensure the flue and air pipe will be side-to-side, as shown...
  • Page 30 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIRECT VENT — — Separate pipes sidewall Use only the vent materials and kits listed in Figure 21, page 24 . Provide pipe adapters if specifi ed. 1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 20, page 23 .
  • Page 31 3. Use a sidewall termination plate as a template for correct location of hole centers. a. Sidewall termination plates for 3” PVC piping are included with the Weil-McLain sidewall vent/air plate kit, shipped with each boiler. b. For 3” AL29-4C vent pipe (with 3” PVC air pipe) or for 2”...
  • Page 32 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIRECT VENT — — Concentric horizontal 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 24 . Provide pipe adapt- ers if specifi...
  • Page 33 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIRECT VENT — (continued) See notices on previous page. Termination location — concentric termination — multiple boilers — clearance from vent of one to air intake of the next 1. Assemble the vent termination as described for concentric termi- nations, on page 38.
  • Page 34 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIRECT VENT — Separate pipes vertical termination Use only the vent materials and kits listed in Figure 21, page 24 . Provide pipe adapt- ers if specifi ed. 1. Locate the terminations such that the total air pip- ing and vent piping from the boiler to the termina- tion will not exceed the maximum length given in Figure 20, page 23 .
  • Page 35 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIRECT VENT — (continued) See notices on previous page. Terminations for multiple boilers 1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
  • Page 36 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIRECT VENT — — Concentric vertical 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 21, page 24 . Provide pipe adapt- ers if specifi...
  • Page 37 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIRECT VENT — (continued) See notices on previous page. Vertical termination — 3” PVC concentric — single or multiple boilers 2. Place roof penetrations to obtain minimum of 12 inches between centers of adjacent vent pipe of another boiler for U.
  • Page 38 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Concentric termination, typical (sidewall or vertical) concentric termination assembly — DO NOT — Inner PVC pipe (vent) attach the rain cap until the termination has been Outer PVC pipe (air) Y fitting inserted through the roof or wall and all supports Rain cap have been installed.

  • Page 39: Vent And Air Piping And Boiler Connections

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Vent and air piping and boiler connections Follow termination instructions Boiler vent and air connections 1. Read and follow all instructions for the termination type used before proceeding with this page. Follow all instructions provided by vent pipe manufacturer.

  • Page 40: Install Water Piping

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Install water piping Use two wrenches when tightening water piping 2. The internal expansion tank is suitable for most systems with at boiler, using one of the wrenches to prevent total volume of 15 gallons or less. See page 45 for suggestions the boiler interior piping from turning.

  • Page 41: Boiler Circulator

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Install water piping (continued) Head loss through boiler internal Boiler circulator piping 1. The boiler circulator is factory-installed in the boiler as shown in this manual. The boiler circulator is selected to ensure (internal by-pass valve OPEN) adequate flow through the WM97+ boiler.

  • Page 42: Install Relief Valve

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Install water piping (continued) Simplified pipe/circulator selection Install relief valve 1. Install relief valve in ¾” street elbow piped from boiler supply 1. Install the boiler and piping using the recommended piping piping tee (Figure 6, page 14).

  • Page 43: Internal Water Piping — Wm97+70 And 110

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Internal water piping — WM97+70 and 110 Set primary/secondary by-pass valve internal piping with by- WM97+70 or 110 only pass valve (boiler circulator provides system flow) — some 1. The primary/secondary by-pass valve (item 5 in the illustrations components omitted for clarity —...

  • Page 44: Internal Water Piping — Wm97+155

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Internal water piping — WM97+155 1. The primary/secondary by-pass valve (item 5 in the illus- Set primary/secondary by-pass valve trations at right) is always left OPEN unless the boiler is WM97+155 only connected to a multiple-boiler manifold (and the internal circulator provides flow only in the interconnecting piping between the boiler and the manifold).

  • Page 45: Expansion Tank — Wm97+70 And 110

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Expansion tank — WM97+70 and 110 Supplementary expansion tank, if required external expansion tank — piping, diaphragm or bladder-type systems having volumes more than 15 gallons only 1. The boiler is equipped with an internal diaphragm-type expansion tank, factory charged to 12 PSIG.

  • Page 46: Expansion Tank — Wm97+155

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Expansion tank — WM97+155 Expansion tank external expansion tank piping, diaphragm or bladder-type Figure 51 and Figure 52 show typical installations of the system expansion tank. Always locate the air separator and expansion tank as shown in the suggested piping drawings, beginning on page 50.

  • Page 47: Verify The Application Will Work

    DHW tank or Aqua Logic (CWH). If domestic priority is has ended (called post-pump). The by-pass required, use a Weil-McLain WMZV zone controller to operate pressure regulator prevents dead-heading zones and activate the boiler.

  • Page 48: System Piping

    System piping DHW refers to an indirect-fired domestic (continued) hot water storage tank. CWH refers to a Weil-McLain Aqua Logic Water Heater. Zone valve zoning — direct connection The system must meet the following (boiler primary/secondary by-pass valve CLOSED) requirements when applying Figure 54...
  • Page 49 67, for instructions on wiring to zone valves. Connect system circulator to CIRC 2 output. 2. The boiler and zone valves can also be operated by a Weil-McLain WMZV Use isolation relays if connected 3-wire zone valve end zone controller.
  • Page 50 67, for instructions on wiring to zone valves. Connect system circulator to CIRC 2 output. 2. The boiler and zone valves can also be operated by a Weil-McLain Use isolation relays if connected 3-wire zone valve end WMZV zone controller.
  • Page 51 (CWH) plus two space heating, or three space heating). Refer to Field wiring, beginning on page 67, for instructions on wiring to circulators. 2. For more than three zones, use a Weil-McLain WMCR zone controller. See suggested wiring in this manual.
  • Page 52 (CWH) plus two space heating, or three space heating). Refer to Field wiring, beginning on page 64, for instructions on wiring to circulators. 2. For more than three zones, use a Weil-McLain WMCR zone controller. See suggested wiring in this manual.
  • Page 53 (CWH) plus two space heating, or three space heating). Refer to Field wiring, beginning on page 67, for instructions on wiring to circulators. 2. For more than three zones, use a Weil-McLain WMCR zone controller. See suggested wiring in this manual.
  • Page 54 (CWH) plus two space heating, or three space heating). Refer to Field wiring, beginning on page 67, for instructions on wiring to circulators. 2. For more than three zones, use a Weil-McLain WMCR zone controller. See suggested wiring in this manual.
  • Page 55 1. The WM97+ control operates up to three zones (DHW plus two space heating). Refer to Field wiring, beginning on page 67, for instructions on wiring to circulators. 2. For more than three zones, use a Weil-McLain WMCR zone controller. See suggested wiring in this manual. Isolation valves.
  • Page 56 1. The WM97+ control operates up to three zones (DHW plus two space heating). Refer to Field wiring, beginning on page 67, for instructions on wiring to circulators. 2. For more than three zones, use a Weil-McLain WMCR zone controller. See suggested wiring in this manual. Isolation valves.
  • Page 57 67, for instructions on wiring to zone valves. Use isolation relays if connected 3-wire zone valve end 2. The boiler and zone valves can also be operated by a Weil-McLain switches to the WM97+ control inputs.
  • Page 58 67, for instructions on wiring to zone valves. Use isolation relays if connected 3-wire zone valve end 2. The boiler and zone valves can also be operated by a Weil-McLain switches to the WM97+ control inputs.

  • Page 59: Multiple Boiler Installations

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Multiple boiler installations Placing multiple boilers Side-to-side mounting of multiple WM97+ boilers 1. Locate multiple boilers with spacings shown in Figure 66. 2. Provide indicated clearances around boilers for access and servic- ing.
  • Page 60 FIRED WATER BOILER Multiple boiler installations (continued) Sequencing multiple WM97+ boilers 1. Use a multiple-boiler controller, such as the Weil-McLain BCP, BMC or BSC, to sequence boilers. Locate temperature sensors as required in the controller manual. Easy-Fit® piping installation 1. Main header and Easy-Fit® Manifold pipe sizing.
  • Page 61 Multiple boiler installations (continued) Piping schematic — typical piping for multiple WM97+ boilers, using Weil-McLain Easy-Fit manifolds (shown using WM97+155 boilers — adjust boiler connections as required for other boiler models) for multiple boiler installations piped as shown in this manual. This allows the boiler internal circulator to circulator water to and from the manifolds.
  • Page 62 FIRED WATER BOILER Multiple boiler installations (continued) Piping layout — typical piping for multiple WM97+ boilers, using Weil-McLain Easy-Fit manifolds (2-boiler system) (shown using WM97+155 boilers — adjust boiler connections as required for other boiler models) for multiple boiler installations piped as shown in this manual.
  • Page 63 This allows the boiler internal circulator to circulator water to and from the manifolds. Flow/check valve (integral to each Indirect-fired storage water heaters (Weil-McLain PLUS Line shown) This piping is suggested only. The boiler internal circulator).
  • Page 64 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Multiple boiler installations (continued) Piping layout — typical piping for multiple WM97+ boilers, using isolation exchanger (shown using WM97+155 boilers — adjust boiler connections as required for other boiler models) Use isolation heat exchanger for: 1.

  • Page 65: Install Condensate Line

    (typically with a pH from 3.2 to 4.5). Install a neutralizing filter when draining into metal pipe and if required by local codes. See Replacement parts section at the end of this manual for the Weil-McLain kit. – 65 – Part number 550-142-204/0117...

  • Page 66: Gas Piping

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Gas piping WM97+ boilers are shipped ready to fire natural when tightening gas gas ONLY. You must install the propane orifice piping at boiler, using one wrench to pre- bushing if the boiler will be connected to propane. vent the boiler gas line connection from See page 15.

  • Page 67: Field Wiring

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Field w iring Wiring must be N.E.C. Class 1. If original wiring — For your as supplied with boiler must be replaced, use safety, turn off electrical power supply at service only type 105 °C wire or equivalent.
  • Page 68 2. Control options require that DHW tanks be controlled from Zone 1 — CIRC1 and ZONE1 cir- if domestic water priority is required. cuits are dedicated to the Weil-McLain 3. ALWAYS connect the DHW circulator to Zone 1 if domestic prior- Aqua Logic Water Heater and cannot be ity is required.
  • Page 69 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Field wiring (continued) Low voltage wiring (24 VAC) WM97+ input and output connections (24VAC) Make the following low-voltage connections, some of which depend on your system and how the WM97+ control will be programmed. The callouts below refer to Figure 79.

  • Page 70: Wiring Diagram — Schematic

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Wiring diagram — schematic WM97+ schematic wiring diagram (see Figure 81, page 71 for legend and notes) – 70 – Part number 550-142-204/0117...

  • Page 71: Wiring Diagram — Ladder

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Wiring diagram — ladder WM97+ ladder wiring diagram (see Figure 80, page 70 for schematic wiring diagram) – 71 – Part number 550-142-204/0117...

  • Page 72: Express Setup — Using Default Settings

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER EXPRESS SETUP — using default settings — Using default control settings ( The following settings must be checked and primary/secondary piping adjusted if necessary: BOILER MODEL and HIGH ALTITUDE in BOILER SETTINGS menu.

  • Page 73: Figure 83

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER EXPRESS SETUP — using default settings (continued) Figure 83 Figure 84 Using default control settings ( No DHW Using default control settings ( No DHW ZONE VALVE-zoned systems ZONE VALVE-zoned systems primary/secondary piping direct connection piping ( for WM97+155)

  • Page 74: Wm97+ Control Operation

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER WM97+ Control operation Figure 85 Control sequence of operation Temperature settings — You must ensure that Display Control action the WM97+ control is set for the proper water status (also see Figure 86, page 75) temperatures for the system.
  • Page 75 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER WM97+ Control operation (continued) Aqua Logic (CWH) Installations — See Aqua Logic manual for additional screen information. When the WM97+ Figure 86 WM97+ control display screens and typical navigation control detects the CWH temperature sensors, it automati- cally enables the CWH screens and CWH control operation.

  • Page 76: Essential Settings

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER ESSENTIAL settings . Failure THE CONTROL SETTINGS LISTED BELOW MUST BE MADE BEFORE STARTING THE BOILER to comply could result in incorrect operation of the boiler, causing possible severe personal injury, death or sub- stantial property damage.

  • Page 77: Wm97+ Control Settings

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER WM97+ Control settings Aqua Logic (CWH) Installations — See Aqua Logic Water Heater manual for additional screen information. When the WM97+ control detects the combi temperature Figure 87 WM97+ control menu access — accessing sensors, it automatically enables the CWH screens and CWH contractor menu control operation.

  • Page 78: Boiler Settings Menus

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER BOILER SETTINGS menus Figure 88 BOILER SETTINGS menus (see Figure 89, page 79 for setting values and descriptions) – 78 – Part number 550-142-204/0117...

  • Page 79: Boiler Model

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER BOILER SETTINGS menus (continued) BOILER MODEL HIGH LIMIT TEMPERATURE The boiler’s high limit temperature during normal Check the boiler model against the model listed on operation is fixed at 200°F and cannot be changed. the boiler’s rating plate.

  • Page 80: Heat Settings Menus

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER HEAT SETTINGS menus Figure 90 HEAT SETTINGS menus (see Figure 92, page 82 for setting values and descriptions). See table below for system type explanations Speed settings — See page 100 for blower speed adjustment procedure and acceptable speeds.
  • Page 81 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER HEAT SETTINGS menus (continued) HEAT SETTINGS Figure 91 Typical outdoor reset curves 1. The heat settings menus are for setting control operation during space heating. The settings apply to all space heating zones. See Fig- ure 92, page 82 for a listing of menu listings.
  • Page 82 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER HEAT SETTINGS menus (continued) 4. Boost will continue until the setpoint (target temperature) amount of time after the burner is shut down when the call reaches the MAX SUPPLY setting. for heat is satisfied. 5.

  • Page 83: Dhw Settings Menus

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DHW SETTINGS menus Aqua Logic (CWH) Installations — See Aqua Logic Water Heater manual for screen information. When the WM97+ control detects the combi temperature sensors, it Figure 93 DHW SETTINGS menus (see Figure 94, page 84 for automatically enables the CWH screens and CWH control operation.
  • Page 84 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DHW SETTINGS menus (continued) TEMPERATURES (DHW) Aqua Logic (CWH) Installations — See Aqua Logic manual for control settings information. — The WM97+ control gives priority DHW priority to DHW operation. During DHW call for heat, the space heating zone ouputs (Zone 2 and Zone 3) are TIMES (DHW TIMES) disabled.

  • Page 85: Circulator Exercising And Freeze Protection Circulators Menus

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER CIRCULATOR EXERCISING and FREEZE PROTECTION CIRCULATORS menus Figure 95 CIRCULATOR (SYSTEM SETTINGS) menu navigation (see Figure 87, page 77 for access information) 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: ###...

  • Page 86: Diagnostic Menu

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIAGNOSTIC menu Figure 96 DIAGNOSTICS menu navigation (see Figure 87, page 77 for access information) Menus Next screen Next screen Next screen Next screen Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS TEMPERATURES STATUS:...
  • Page 87 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 97 DIAGNOSTICS menu details (see Figure 96, page 86 for access information) Menu/Item Units High Default Comment Value Value TO RESET ALL HISTORY To reset all history counters to zero: Enter the DIAGNOSTICS menu. Then press and hold the left COUNTERS TO ZERO: and right arrows located below the control display.
  • Page 88 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 98 DIAGNOSTICS menu details (continued) (see Figure 96, page 86 for access information) Menu/Item Units High Default Comment Value Value TO RESET ALL HISTORY To reset all history counters to zero: Enter the DIAGNOSTICS menu. Then press and hold the left COUNTERS TO ZERO: and right arrows located below the control display.

  • Page 89: Maintenance, Date And Time Menus

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER MAINTENANCE, DATE AND TIME menus Figure 99 MAINTENANCE, DATE AND TIME menus — navigation (see Figure 87, page 77 for access information) MAINTENANCE INFO NAME ################ PHONE ###-###-#### MODEL WM97+ ### ########## INSTALLED MM/DD/YY...

  • Page 90: Water Chemistry

    Startup — fill the system Clean system to remove sediment Antifreeze 1. Use only antifreeze listed by Weil-McLain as suitable for 1. You must thoroughly flush the system (without boiler use with WM97+ Gas Boilers. See Figure 130, page 127 for connected) to remove sediment.
  • Page 91 Test antifreeze concentration at least annually. If concentra- plication of the antifreeze products listed in tion is low, add antifreeze or drain system and refill with this document only for use in Weil-McLain correct mixture. WM97+ boilers. Do not apply these prod- ucts or instructions for other applications.

  • Page 92: Check Thermostat Circuits

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Startup — fi nal checks Inspect/fi ll condensate system Check for gas leaks Inspect/check condensate lines and fi ttings 1. Inspect the condensate drain line, condensate PVC fi ttings and Before starting the boiler, and during initial opera- condensate trap.
  • Page 93 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Startup — final checks (continued) If you discover evidence of any gas leak, shut down Final checks before starting boiler the boiler at once. Find the leak source with bubble ❏ Read the instructions to adjust and set up the WM97+ test and repair immediately.
  • Page 94 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Startup — final checks (continued) Figure 102 Operating instructions (WARNING — Verify that the WM97+ control is set for the correct boiler model before proceeding.) – 94 – Part number 550-142-204/0117...
  • Page 95 AUTO. DO NOT adjust throttle on low fi re. into the boiler enclosure. Failure to com- ply could result in severe personal injury, 7. Consult your local Weil-McLain representative if acceptable results death or substantial property damage. cannot be obtained for both high and low fi re.
  • Page 96 If results are acceptable at low fi re, verify high fi re readings again. Restore fi ring rate to AUTO. DO NOT adjust throttle on low fi re. 7. Consult your local Weil-McLain representative if acceptable results cannot be obtained for both high and low fi re.
  • Page 97 AUTO. DO NOT adjust throttle on low fi re. weepage or other indications that there might 7. Consult your local Weil-McLain representative if acceptable results be leakage, follow the procedure for checking the heat exchanger-to-condensate dish seal on cannot be obtained for both high and low fi...

  • Page 98: Check-Out/Startup Verification

    Installation certificate Thermostat circuit wiring checked to ensure there are no stray voltages? ❏ Fill out the warranty registration card and send to Weil-McLain. ❏ Followed Operating Instructions, Figure 102, page 94? ❏ Return instructions to envelope and give to owner or place ❏...

  • Page 99: Annual Startup And General Maintenance

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Annual startup and general maintenance Follow the service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death or substantial property damage.

  • Page 100: Annual Startup

    FIRED WATER BOILER Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS It is recommended that you obtain a Weil-McLain WM97+ Boiler Maintenance kit before attempting REMOVING BURNER GASKET or the first-year inspection, to ensure all parts that COVER PLATE INSULATION .

  • Page 101: Address Reported Problems

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Annual startup (continued) Clean condensate trap The boiler should be inspected and 1. See Figure 108. started annually, at the beginning of the heating season, only by a qualified 2. Slide bracket off of condensate trap then disconnect top nut service technician.
  • Page 102 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Annual startup (continued) Do not use automatic air vents in systems with closed- Check air openings type tanks. The air will escape from the system instead 1. Verify that combustion and ventilation air openings to the of returning to the tank.

  • Page 103: Check Control Settings

    1. Inspect all boiler wiring, making sure wires are in good condi- ceptable, check combustion values. If combustion is properly tion and securely attached. adjusted, obtain a replacement burner from Weil-McLain. 2. Verify that all connectors are securely inserted. Check flame signal Check control settings 1.

  • Page 104: Note 1

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Annual startup (continued) Check blower speeds Figure 110 Firing rates and corresponding blower speeds (low fire, ignition, and high fire) — for altitudes up to 5,500 1. For installations at altitudes above 5,500 feet, feet and high altitude (above 5,500 feet) make sure the control is set up for high altitude in the boiler setup menu.
  • Page 105 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Annual startup (continued) Check boiler relief valve Reinstall jacket door after servicing 1. Inspect the relief valve and lift the lever to verify flow as in the following warnings, excerpted from a relief valve manufac- turer’s warning label.

  • Page 106: Troubleshooting

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Troubleshooting Before calling for troubleshooting assistance, fi ll in the “ WM97+ Gas Data Collection Sheet ” ( page 144 ). 1. See Figure 111 for tools and kits recommended for troubleshoot- ing WM97+ boilers.

  • Page 107: Checking Temperature Sensors

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Check WM97+ control fuses Figure 113 Control housing lifted to slot 2 (jacket door removed and inlet air silencer ALWAYS check WM97+ control fuses before replacing rotated out of the way) (WM97+70 WM97+ control or any major components (blower, etc.).
  • Page 108 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a com- plete diagnosis. WM97+ control fault indications 1. The WM97+ control provides diag- 2.
  • Page 109 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Figure 117 Troubleshooting suggestions for WM97+ boilers — WM97+ control Error Condition Log The WM97+ control is able to record information about the boiler’s condition at the time of the three previous faults or errors. This information is available to view in Contractor Menus under “DIAGNOSTICS”...
  • Page 110 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Figure 118 Troubleshooting suggestions for WM97+ boilers — Fault displays, diagnostics and corrective actions Condition Diagnostics Corrective Action(s) Display Control is not receiving 24V Check wiring for short circuit or Correct wiring per wiring diagram including connection of transformer Nothing shown power...
  • Page 111 Manual reset is required if the Inspect vent system for abnormal wear or damage. temperature rises above 225°F. Reset using manual reset screen Contact Weil-McLain Technical Support. on display. Occurs if internal low water Automatic reset occurs if Check for low water condition in system. Repair system as necessary LOW WTR cutoff...
  • Page 112 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Figure 118 Troubleshooting suggestions for WM97+ boilers — Fault displays, diagnostics and corrective actions (cont.) Condition Diagnostics Corrective Action(s) Display Occurs if manual or automatic Automatic external limit will Is there an external safety device connected? If yes, trouble shoot the LIMIT OPEN reset l imit op ens.
  • Page 113 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Troubleshooting (continued) Figure 118 Troubleshooting suggestions for WM97+ boilers — Fault displays, diagnostics and corrective actions (cont.) Condition Diagnostics Corrective Action(s) Display BLOWER FAULT Blower unable to reach Reset using manual reset screen Check wire harness for loose connections and pin engagement at blower required speed or does not on display;...

  • Page 114: Maintenance

    2. Purchase the circulator cartridge, available through Failure to replace damaged components and to use Weil-McLain distributors. Find the cartridge part number on only the parts specifically intended for the boiler can the circulator label or in Figure 137, page 134 (WM97+70 or result in severe personal injury, death or substantial 110) or (WM97+155).
  • Page 115 Adding water to exchanger for SIDE, when required condensate dish seal check 1. Isolate the boiler from the heating system. 2. Obtain Sentinel X400 cleaner from Weil-McLain. Follow instruc- tions supplied with the cleaner to clean the boiler heat exchanger. Funnel Funnel Use ONLY the cleaning product available from Weil- McLain, Sentinel X400.

  • Page 116: Cleaning Heat Exchanger Flue Side, 70

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 70 Cleaning the WM97+ 70 heat Figure 122 Legend for Figure 123, page 117 exchanger FLUE SIDE or accessing the burner, if required A Boiler interior 6 Heat exchanger cover plate The boiler contains ceramic fiber materials.
  • Page 117 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 70 (continued) Figure 123 Accessing the burner or heat exchanger (see Legend on next page) – 117 – Part number 550-142-204/0117...
  • Page 118 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 70 (continued) protected from damage. If the refractory is damaged, it 4. Slide the refractory (item 12) over the burner. Align the must be discarded and replaced with a new one. refractory and press in place.

  • Page 119: Cleaning Heat Exchanger Flue Side, 110

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 110 silencer clip from the flexible gas line by rotating to the right. Cleaning the WM97+110 heat Spread the backside of the clip attached to the silencer to exchanger FLUE SIDE or accessing aid in this rotation.
  • Page 120 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 110 (continued) Handle the cover plate/burner assembly carefully to avoid damage to the components or refractory. Place Figure 124 Legend for Figure 125, page 121 the assembly on a clean, flat surface. Boiler interior 4 Air silencer clip Inspect refractory and replace if damaged...
  • Page 121 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 110 (continued) Figure 125 Accessing the burner or heat exchanger WM97+ 110 (see Legend on page 120) – 121 – Part number 550-142-204/0117...
  • Page 122 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger fl ue side, 110 (continued) Figure 126 Accessing the burner or heat exchanger WM97+ 110 (see Legend on page 120 ) – 122 – Part number 550-142-204/0117...

  • Page 123: Cleaning Heat Exchanger Flue Side, 155

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 155 exchanger. This gasket is graphite and may pull apart or stick Cleaning the WM97+155 heat to the burner on removal. exchanger FLUE SIDE or accessing 5.
  • Page 124 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 155 (continued) Inspect refractory and replace burner gasket Figure 127 Legend for Figure 128, page 125 1. See Figure 128, page 125 part D. a. Inspect the refractory to make sure it is intact, with no Boiler interior Air silencer clip visible damage.
  • Page 125 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Cleaning heat exchanger flue side, 155 (continued) Figure 128 Accessing the burner or heat exchanger (see Legend on next page) – 125 – Part number 550-142-204/0117...

  • Page 126: Replacement Parts

    100 of this manual. Failure to comply could result in severe personal injury. Weil-McLain part numbers are found in this manual and in Weil-McLain Boilers and Con- trols Repair Parts Lists. REINSTALL JACKET DOOR Inspect boiler jacket front door gaskets and reinstall boiler jacket front door after start or servicing.
  • Page 127 2PPS-HTP 2” polypropylene pipe ... . Weil-McLain sidewall vent/air cap termination kit for 383-500-397 3PPS-HTP 3” polypropylene pipe ... .
  • Page 128 Gasket only 590-318-059 Aqua Logic (CWH) wire harness opening plugs One plug 561-444-190 561-444-190 (not shown) Condensate bracket kit (not shown) Bracket and two plastic rivets 383-700-238 383-700-239 Go to www.weil-mclain.com to locate Weil-McLain distributors – 128 – Part number 550-142-204/0117...
  • Page 129 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Replacement parts (continued) Figure 132 Jacket assembly — WM97+70/110/155 (see Figure 131, page 128 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 129 – Part number 550-142-204/0117...
  • Page 130 Burner, gasket, and hardware (includes item 250) 383-700-106 383-700-246 Burner gasket 383-700-107 383-700-247 Heat exchanger water temperature sensor (one sensor for either boiler inlet or outlet water 511-724-296 temperature) Go to www.weil-mclain.com to locate Weil-McLain distributors – 130 – Part number 550-142-204/0117...
  • Page 131 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Replacement parts (continued) Figure 134 WM97+70/110 Heat exchanger assembly (see Figure 133, page 130 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 131 – Part number 550-142-204/0117...
  • Page 132 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Replacement parts (continued) Figure 135 WM97+155 Heat exchanger assembly parts (see Figure 136, page 133 for illustration) Item Name Part Number Heat exchanger 383-700-197 Heat exchanger, condensate dish, cover plate, burner, igniter, sight glass, refractory, water sensors, gaskets, silicone, and hardware 383-700-180 (includes items 120, )
  • Page 133 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Replacement parts (continued) Figure 136 WM97+155 Heat exchanger assembly parts (see Figure 135, page 132 for part numbers) – 133 – Part number 550-142-204/0117...
  • Page 134 Gasket - lower pipe Gasket - lower pipe to cabinet 590-300-037 Gasket - upper pipe Gasket - upper pipe to cabinet 590-318-050 Low water cutoff Low water cutoff 383-600-069 Go to www.weil-mclain.com to locate Weil-McLain distributors – 134 – Part number 550-142-204/0117...
  • Page 135 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Replacement parts (continued) Figure 138 Piping components for WM97+70/110 (see Figure 136, page 133 for part numbers) – 135 – Part number 550-142-204/0117...
  • Page 136 6KLSSHG ORRVH IRU ¿HOG LQVWDOODWLRQ 383-000-000 Relief valve  36,* UHOLHI YDOYH ² VKLSSHG ORRVH IRU ¿HOG LQVWDOODWLRQ 383-500-095 *DV ÀH[ OLQH DGDSWHU 137 WR ÀDUH DGDSWHU 562-302-571 Go to www.weil-mclain.com to locate Weil-McLain distributors – 136 – Part number 550-142-204/0117...
  • Page 137 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Replacement parts (continued) Figure 140 Piping components for WM97+155 (see Figure 139, page 136 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 137 – Part number 550-142-204/0117...
  • Page 138 F2 - 12 amp, fast-blow ag (5 fuses) 5 Fuses 383-500-604 (not shown here — see Figure 115, page 107) Ground wire (not shown) Wire harness ground, igniter to jacket 591-391-991 Go to www.weil-mclain.com to locate Weil-McLain distributors – 138 – Part number 550-142-204/0117...
  • Page 139 — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Replacement parts (continued) Figure 142 Controls and electrical assemblies — WM97+70/110/155 (see Figure 141, page 138 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 139 – Part number 550-142-204/0117...

  • Page 140: Dimensions

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Dimensions Figure 143 Dimensional data — WM97+ Series 2 70/110/155 (all dimensions in inches) (shows fi eld-installed components) (shows fi eld-installed components) RIGHT FRONT RIGHT FRONT 70/110 BOTTOM BOTTOM (shows fi eld-installed components) (shows fi...

  • Page 141: Ratings — Wm97+ Series 2 Boilers

    155,000 143,000 95.1 3” PVC Notes As an Energy Star Partner, Weil-McLain and nothing need be added for normal All vent and air pipe elbows must has determined that WM97+ boilers piping and pickup. Ratings are based be sweep elbows, NOT short-radius...
  • Page 142 Net water ratings are based on piping and 110 155 Note 1 Note 2 Figure 67, page 59 pickup allowance of 1.15. Consult Weil-McLain Technical Services for other allowances. Total amp requirement includes up to three circulators, not exceeding 2.2 amps per circulator. 12.8 Operating weight is the total weight of the boiler, including water.

  • Page 143: Installation And Service Certificate

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER Installation and Service Certificate Boiler Start-Up Data Boiler Model / Series WM97+ ________ / Series ____ Date installed ________________ @: High fire ______% Low fire ______% CP Number ____________ FUEL: Natural ____ LP ____ Btu Input ___________________ CO @: High fire ____ ppm Low fire ____ ppm Flame signal on control display at high fire __________________...

  • Page 144: Wm97+ Series 2 Gas Boiler Data Collection Sheet

    — Boiler Manual WM97+ Series 2 FIRED WATER BOILER WM97+ Series 2 Gas Boiler Data Collection Sheet Customer Info: Maintenance Info: Contact: Name: Contractor: Phone: Job name: Model: City, state: CP#: Distributor: Installed: Boiler/System Piping Details (Please Sketch) System Components: Top: _____ Bottom (DHW): _____ Near boiler pipe size: HEATING:...

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