Weil-McLain WM97+70 Manual
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Weil-McLain WM97+70 Manual

Gas-fired water boiler
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Summary of Contents for Weil-McLain WM97+70

  • Page 2: The Wm97+70 & 110 Gas-Fired Water Boilers

    WM97+ — Boiler Manual fired water boiler The WM97+70 & 110 Gas-fired water boilers to match boiler output to space heating and/or DHW heating 1. Stainless steel firetube heat exchanger demand. The control provides for three heating zones (DHW plus 2.
  • Page 3 WM97+ — Boiler Manual fired water boiler The WM97+70 & 110 Gas-fired water boiler (cont.) – 3 – Part number 550-142-085/0712...

  • Page 4: The Wm97+155 Gas-Fired Water Boiler

    WM97+ — Boiler Manual fired water boiler The WM97+155 Gas-fired water boiler DHW heating demand. The control provides for three heating 1. Stainless steel firetube heat exchanger zones (DHW plus two space-heating or three space heating). DHW 2. Heat exchanger access cover/burner mounting plate direct-connected to the bottom piping connections can be set for domestic priority.
  • Page 5 WM97+ — Boiler Manual fired water boiler The WM97+155 Gas-fired water boiler (continued) – 5 – Part number 550-142-085/0712...

  • Page 6: Table Of Contents

    WM97+ — Boiler Manual fired water boiler Contents The WM97+70 & 110 Gas-fired water boilers DO NOT SERVICE THE The WM97+155 Gas-fired water boiler BOILER WITHOUT A WM97+ Please read before proceeding MAINTENANCE KIT AVAILABLE Boiler location The WM97+ maintenance kit includes components that...

  • Page 7: Please Read Before Proceeding

    If antifreeze is used, a reduced pressure back-flow preventer that has used glycol before installing the new boiler. Use only device shall be used. the products listed by Weil-McLain for use with this boiler. • Sidewall vent air installations — see instruction on page 22.

  • Page 8: Boiler Location

    WM97+ — Boiler Manual fired water boiler Boiler location Installations must comply with: • Ensure that the installation complies with all applicable codes. • Local, state, provincial, and national codes, laws, regulations • Prevent boiler water and condensate from freezing. and ordinances.
  • Page 9 WM97+ — Boiler Manual fired water boiler Boiler location (continued) Provide clearances for service Provide clearances from combustible access — RECOMMENDED materials — REQUIRED 1. See Figure 2 for REQUIRED minimum clearances. ALL installa- 1. See Figure 1 for recommended service clearances. tion must provide at least these minimums.

  • Page 10: Wall-Mounting The Boiler

    Wall-mount bracket and spacer board piping components Figure 4 The operating weights for wall-mountable boilers are: WM97+70 or WM97+110: 140 pounds WM97+155: 150 pounds Failure to comply with above and the procedure given below could result in severe personal injury, death or substantial property damage.
  • Page 11 WM97+ — Boiler Manual fired water boiler Wall-mounting the boiler (continued) Install the wall-mount bracket and Place boiler on wall-mount bracket Figure 5 spacer boards (by installer) 1. See Figure 4, page 10. 2. Locate the studs — must be on 16-inch centers. See previous page instructions if studs are not on 16-inch centers.

  • Page 12: Boiler Hydrostatic Test

    WM97+ — Boiler Manual fired water boiler Boiler hydrostatic test Fill and pressure test DO NOT install a relief valve with a . This pressure higher than 30 PSIG is the maximum allowable relief valve 70/110 models only: CLOSE the internal expansion tank setting for the WM97+ boiler.
  • Page 13 4 Pressure/temperature gauge, shipped loose with boiler 5 Street ell, ¾” NPT, shipped loose with boiler, for mounting boiler relief valve For WM97+70 or 110, rotate the street ell to about 30° off center, as shown, to allow room for the relief valve discharge piping.

  • Page 14: Converting Boiler To Propane - Wm97+70/110

    Converting boiler to propane — WM97+70/110 Propane gas orifice bushing identification Figure 8 Prepare boiler for propane — WM97+70 on left (may be stamped 3.85) WM97+70/110 only WM97+110 on right (may be stamped 4.45) (if required) Propane operation...
  • Page 15 WM97+ — Boiler Manual fired water boiler Converting boiler to propane — WM97+70/110 (cont.) Installing the propane gas orifice bushing (some details omitted for clarity) Figure 10 7. See Figure 10. Insert the propane gas orifice bushing (item 4) into the gas valve outlet as shown.

  • Page 16: Converting Boiler To Propane - Wm97+155

    WM97+ — Boiler Manual fired water boiler Converting boiler to propane — WM97+155 Support the gas valve after disconnect- Prepare boiler for propane — ing from the venturi. DO NOT allow it WM97+155 only to hang from the gas valve flex line. When re-attaching the gas valve, ensure the (when required) gas valve grommet (item 8, Figure 13) is in...
  • Page 17 WM97+ — Boiler Manual fired water boiler Converting boiler to propane — WM97+155 (cont.) Installing the propane gas orifice bushing (some details omitted for clarity) Figure 12 Gas valve and venturi Figure 13 LEGEND for Figure 12 amd Figure 13 Venturi (leave venturi attached to blower) (3) hex-head screws, 5 mm hex (remove and retain) Honeywell gas valve...

  • Page 18: Gas Piping - Sizing Gas Lines

    Maximum: 13” (330 mm) w.c. with no flow (lockup). b. Minimum gas pressure, with gas flowing (verify during boiler startup, while boiler is at high fire): WM97+70: 3½” (89 mm) w.c. Equivalent lengths of straight pipe for WM97+110: 4½” (114 mm) w.c.

  • Page 19: Venting/Air Piping - General

    WM97+ — Boiler Manual fired water boiler Venting/air piping — general You must pipe combustion air to the Do not install the WM97+ boiler into a common vent with boiler air intake any other appliance. This will cause flue gas spillage or ap- Install air inlet piping for the WM97+ pliance malfunction, resulting in possible severe personal boiler as described in this manual.
  • Page 20 Maximum vent lengths apply for either 2” or 3” vent and air pipe. If using 2” pipe, provide 3”x2” 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 132, page 129 for derate amounts.
  • Page 21 Metal-Fab, Inc. — CORR/GUARD steel Centrotherm Eco Systems — InnoFlue® Weil-McLain stainless steel bird screens, 2” or 3” (purchase separately) — see Figure 119, page 117 for part numbers Note 1: Weil-McLain concentric vent kits are made from PVC ADAPTERS — AL29-4C piping — Install a PVC-to- pipe and fittings.

  • Page 22: Commonwealth Of Massachusetts Installations

    WM97+ — Boiler Manual 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 23: Vent Termination Requirements

    WM97+ — Boiler Manual fired water boiler Vent termination requirements The vent termination must be located to meet all requirements below (also applies to vertical vent Figure 19 terminations). For Canadian installations, defer to the requirements of CSA B149.1 or B149.2 Installation Code. –...

  • Page 24: Boiler Room Air Openings

    WM97+ — Boiler Manual fired water boiler Boiler room air openings Combustion and ventilation air openings for WM97+ Direct Vent installations Figure 20 The WM97+ boiler CANNOT be in the same space with other appliances if clearances around the WM97+ are less than the recommended service clearances shown in Figure 1, page 9.

  • Page 25: Direct Vent - Sidewall With W-M Vent/Air Plate

    All vent pipes and air inlets must ter- minate at the same height to avoid pos- Step 7 The Weil-McLain plate termination must be installed before piping sibility of severe personal injury, death or from the boiler to the termination.
  • Page 26 Level the template with a level. Hole preparation in wall — INSIDE VIEW Figure 23 For the Weil-McLain plate, the template must be level to (use template provided) ensure the flue and air pipe will be side-to-side, as shown in Figure 23.

  • Page 27: Direct Vent - Sidewall With Separate Pipes

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & — Separate pipes sidewall Figure 25 INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 18, page 21. Provide pipe adapters if specified.
  • Page 28 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 29: Direct Vent - Sidewall Concentric

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Sidewall concentric Allowable vent/air pipe materials & — Concentric horizontal Figure 28 INSTALLATION SEQUENCE lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 18, page 21.
  • Page 30 WM97+ — Boiler Manual fired water boiler DIRECT VENT — Sidewall concentric (continued) Termination location — concentric See notices on previous page. Figure 29 termination — multiple boilers — clearance from vent of one to air intake of Install termination — concentric pipes the next 1.

  • Page 31: Direct Vent - Vertical With Separate Pipes

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & Separate pipes vertical termination Figure 31 lengths Use only the vent materials and kits listed in Figure 18, page 21. Provide pipe adapt- ers if specified.
  • Page 32 WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical with separate pipes (continued) Terminations for multiple boilers See notices on previous page. Figure 32 Prepare roof penetrations 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 33: Direct Vent - Vertical Concentric

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical concentric Allowable vent/air pipe materials & — Concentric vertical Figure 33 INSTALLATION SEQUENCE lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 18, page 21.
  • Page 34 WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical concentric (continued) Vertical termination — 3” PVC concentric See notices on previous page. Figure 34 — 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 35: Concentric Termination, Typical (Sidewall Or Vertical)

    WM97+ — Boiler Manual fired water boiler Concentric termination, typical (sidewall or vertical) concentric termination assembly — DO NOT LEGEND for Figure 36 Figure 36 PVC attach the rain cap until the termination has been 1 — Inner PVC pipe (vent) 4 —...

  • Page 36: Vent And Air Piping And Boiler Connections

    WM97+ — Boiler Manual fired water boiler Vent and air piping and boiler connections Follow termination instructions Boiler vent and air connections Figure 37 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 37: Install Water Piping

    Do not plug or place any only, not on WM97+155) obstruction in the discharge line. 1. The WM97+70 and 110 boilers are equipped with an internal Test the operation of the valve after fill- expansion tank, factory charged to 12 PSIG.

  • Page 38: Internal Water Piping - Wm97+70 And

    WM97+ — Boiler Manual fired water boiler Internal water piping — WM97+70 and 110 Set primary/secondary by-pass valve WM97+70/110 internal piping with by- Figure 38 WM97+70 or 110 only pass valve (boiler circulator CLOSED provides system flow) — some 1. The primary/secondary by-pass valve (item 5 in the illustrations componensts omitted for clarity —...

  • Page 39: Internal Water Piping - Wm97+155

    WM97+ — Boiler Manual fired water boiler Internal water piping — WM97+155 Set primary/secondary by-pass valve 1. The primary/secondary by-pass valve (item 5 in the illus- 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 The internal primary/secondary valve MUST between the boiler and the manifold).

  • Page 40: Expansion Tank - Wm97+70 And

    WM97+ — Boiler Manual fired water boiler Expansion tank — WM97+70 and 110 Supplementary expansion tank, if required WM97+70/110 external expansion tank Figure 42 — 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 41: Expansion Tank - Wm97+155

    WM97+ — Boiler Manual fired water boiler Expansion tank — WM97+155 Expansion tank WM97+155 external expansion tank Figure 44 piping, diaphragm or bladder-type Figure 44 and Figure 45 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 45.

  • Page 42: System Piping

    WM97+70 or 110 only by-pass valve CLOSED) (See next page for legend) The WM97+70 or 110 boiler internal circulator can be used to circulate many heating systems using the arrangement shown in Figure 46 and in Figure 47, page 43.

  • Page 43: Boiler Model

    DHW refers to an indirect-fired domestic hot (continued) water storage tank. CWH refers to a Weil- McLain Companion Water Heater. WM97+70/110 Zone valve zoning — direct connection The system must meet the following Figure 47 Figure 48 (boiler primary/secondary by-pass valve CLOSED)
  • Page 44 See Figure 49. 1. This configuration is for WM97+70 or 110 zone valve systems that need more flow than the boiler’s circulator can provide (see page 43 for infor- mation).
  • Page 45 Connect system circulator to CIRC 2 output. on page 62, for instructions on wiring to zone valves. 2. The boiler and zone valves can also be operated by a Weil-McLain Use isolation relays if connected 3-wire zone valve end switches to the WM97+ control inputs.
  • Page 46 Refer to Field wiring, begin- ning on page 62, 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 47 Refer to Field wiring, begin- ning on page 62, 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 48 Refer to Field wiring, beginning on page 62, for instructions on wiring to circulators. 2. For more than three zones, use a Weil-McLain WMCR zone controller. See sug- gested wiring in this manual. Legend — Figure 53...
  • Page 49 Refer to Field wiring, beginning on page 62, 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. Legend — Figure 54...
  • Page 50 1. The WM97+ control operates up to three zones (DHW plus two space heating). Refer to Field wiring, beginning on page 62, 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. Legend — Figure 55...
  • Page 51 1. The WM97+ control operates up to three zones (DHW plus two space heating). Refer to Field wiring, beginning on page 62, 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. Legend — Figure 56 information —...
  • Page 52 DHW or CWH. Refer to Field wiring, beginning on page 62, 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 WMZV switches to the WM97+ control inputs. zone controller.
  • Page 53 DHW or CWH. Refer to Field wiring, beginning on page 62, for instructions on wiring to zone valves. Use isolation relays if connected 3-wire zone valve end The boiler and zone valves can also be operated by a Weil-McLain WMZV switches to the WM97+ control inputs. zone controller.

  • Page 54: Multiple Boiler Installations

    WM97+ — Boiler Manual fired water boiler Multiple boiler installations Placing multiple boilers Side-to-side mounting of multiple WM97+ Figure 59 boilers 1. Locate multiple boilers with spacings shown in Figure 59. 2. Provide indicated clearances around boilers for access and servic- ing.
  • Page 55 Multiple boiler installations (continued) Sequencing multiple WM97+ boilers Maximum connected load per manifold: 1. Use a multiple-boiler controller, such as the Weil-McLain BCP, 2-inch manifold — 450 MBH BMC or BSC, to sequence boilers. Locate temperature sensors as required in the controller manual.
  • Page 56 Multiple boiler installations (continued) Piping schematic — typical piping for multiple WM97+ boilers, using Weil-McLain Easy-Fit manifolds (shown Figure 63 using WM97+155 boilers — adjust boiler connections as required for other boiler models) Legend — Figure 63 The boiler internal primary/secondary by-pass valve must be CLOSED for multiple boiler installations piped as shown in this manual.
  • Page 57 Multiple boiler installations (continued) Piping layout — typical piping for multiple WM97+ boilers, using Weil-McLain Easy-Fit manifolds (2-boiler Figure 64 system) (shown using WM97+155 boilers — adjust boiler connections as required for other boiler models) The boiler internal primary/secondary by-pass valve must be CLOSED for multiple boiler installations Legend —...
  • Page 58 This allows the boiler internal circulator to circulator water to and from the manifolds. 1 Flow/check valve (integral to each 21 Indirect-fired storage water heaters (Weil-McLain PLUS Line shown) This piping is suggested only. The boiler internal circulator) —...
  • Page 59 WM97+ — Boiler Manual fired water boiler Multiple boiler installations (continued) Piping layout — typical piping for multiple WM97+ boilers, using isolation exchanger (shown using Figure 66 WM97+155 boilers — adjust boiler connections as required for other boiler models) Use isolation heat exchanger for: 1.

  • Page 60: Install Condensate Line

    The pump should have a minimum capacity of 2 GPH for the WM97+70, 3 GPH for the WM97+110, or 4 GPH for the WM97+155. 3. When sizing condensate pumps, make sure to include the total load of all appliances connected to it.

  • Page 61: Gas Piping

    Check gas pressure at inlet to boiler line if inlet pressure can exceed 13” (330 mm) w.c. at 1. See Figure 96, page 90 (WM97+70/110) or Figure 98, page 91 any time. Adjust lockup regulator for 13” (330 mm) (WM97+155) for location of the gas inlet pressure test port.

  • Page 62: Field Wiring

    (see Figure 73, page 65 and Figure 74, page 66 for detailed schematic and ladder wiring diagrams) (top Figure 70 view shown at bottom right is of WM97+70/100 — electrical entrances for WM97+155 are the same) Line voltage wiring terminals Low voltage wiring terminals See Figure 71, page 63 for wiring instructions.
  • Page 63 ZONE1 circuits are dedicated to the 3. ALWAYS connect the DHW circulator to Zone 1 if domestic prior- Weil-McLain Companion Water Heater ity is required. This can be done if the DHW tank is piped to the and cannot be used for other purposes.
  • Page 64 WM97+ — Boiler Manual fired water boiler Field wiring (continued) Low voltage wiring (24 VAC) WM97+ input and output Figure 72 low voltage connections (24 VAC) 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 72.

  • Page 65: Wiring Diagram - Schematic

    WM97+ — Boiler Manual fired water boiler Wiring diagram — schematic WM97+ schematic wiring diagram (see Figure 74, page 66 for legend and notes) Figure 73 – 65 – Part number 550-142-085/0712...

  • Page 66: Wiring Diagram - Ladder

    WM97+ — Boiler Manual fired water boiler Wiring diagram — ladder WM97+ ladder wiring diagram (see Figure 73, page 65 for schematic wiring diagram) Figure 74 – 66 – Part number 550-142-085/0712...

  • Page 67: Express Setup - Using Default Settings

    WM97+ — Boiler Manual fired water boiler EXPRESS SETUP — using default settings Using default control settings ( — The MANDATORY CONTROL SETTINGS Figure 75 No DHW following settings must be checked and adjusted CIRCULATOR-zoned systems primary/secondary piping if necessary: BOILER MODEL and HIGH AL- TITUDE in BOILER SETTINGS menu.
  • Page 68 WM97+ — Boiler Manual fired water boiler EXPRESS SETUP — using default settings (continued) Using default control settings ( Using default control settings ( Figure 76 Figure 77 No DHW No DHW ZONE VALVE-zoned systems ZONE VALVE-zoned systems primary/secondary piping direct connection piping ( for WM97+155) Legend and guidelines —...

  • Page 69: Wm97+ Control Operation

    WM97+ — Boiler Manual fired water boiler WM97+ control operation Control sequence of operation Figure 78 — You must ensure that the Temperature settings WM97+ control is set for the proper water temperatures Display Control action for the system. Excessive water temperature can cause status (also see Figure 79, page 70) significant property damage in some applications.
  • Page 70 WM97+ — Boiler Manual fired water boiler WM97+ control operation (continued) CWH Installations — See Companion Water Heater manual for additional screen information. When the WM97+ control detects the CWH temperature sensors, it automati- WM97+ control display screens and typical navigation Figure 79 cally enables the CWH screens and CWH control operation.

  • Page 71: Essential Settings

    WM97+ — Boiler Manual 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 72: Wm97+ Control Settings

    WM97+ — Boiler Manual fired water boiler WM97+ control settings CWH Installations — See Companion Water Heater manual for additional screen information. When the WM97+ control detects the combi temperature sensors, it automati- WM97+ control menu access — accessing Figure 80 contractor menus cally enables the CWH screens and CWH control operation.

  • Page 73: Boiler Settings Menus

    WM97+ — Boiler Manual fired water boiler BOILER SETTINGS menus menus (see Figure 82, page 74 for setting values and descriptions) Figure 81 BOILER SETTINGS – 73 – Part number 550-142-085/0712...
  • Page 74 WM97+ — Boiler Manual fired water boiler BOILER SETTINGS menus (continued) BOILER MODEL 2. The HIGH LIMIT TEMPERATURE setting will automatically return to 200°F if power is turned off. The boiler will restart when power is restored. Check the against the model listed on boiler model the boiler’s rating plate.

  • Page 75: Heat Settings Menus

    WM97+ — Boiler Manual fired water boiler HEAT SETTINGS menus menus (see Figure 85, page 77 for setting values and descriptions) Figure 83 HEAT SETTINGS See table below for system type explanations Speed settings — See page 98 for blower speed adjustment procedure and acceptable speeds.
  • Page 76 WM97+ — Boiler Manual fired water boiler HEAT SETTINGS menus (continued) HEAT SETTINGS Typical outdoor reset curves Figure 84 1. The heat settings menus are for setting control operation during space heating. The settings apply to all space heating zones. See Fig- ure 85, page 77 for a listing of menu listings.
  • Page 77 Additional time to run circulators longer than standard 10 second time Postpump Time: ### seconds Circulator run time after call for heat ends Maximum Rate Boiler Model and altitude specific (derated automatically if HIGH ALTITUDE is selected in WM97+70 1100 4300 4150 control setup) WM97+110 1400 5650 5450 NOTE: Adjusting boiler firing rate will affect AFUE rating.

  • Page 78: Dhw Settings Menus

    WM97+ — Boiler Manual fired water boiler DHW SETTINGS menus CWH Installations — See Companion Water Heater man- ual for screen information. When the WM97+ control detects the combi temperature sensors, it automatically enables the menus (see Figure 87, page 79 for Figure 86 DHW SETTINGS setting values and descriptions) CWH screens and CWH control operation.
  • Page 79 Additional time to run circulators longer than standard 10 second time Postpump Time: ### seconds Circulator run time after call for heat ends Maximum Rate Boiler Model and altitude specific WM97+70 1100 4300 4150 (derated automatically if HIGH ALTITUDE is selected in WM97+110 1400...

  • Page 80: Circulator Exercising And Freeze Protection Circulators Menus

    WM97+ — Boiler Manual fired water boiler CIRCULATOR EXERCISING and FREEZE PROTECTION CIRCULATORS menus CIRCULATOR (SYSTEM SETTINGS) menu navigation (see Figure 80, page 72 for access information) Figure 88 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 81: Diagnostic Menu

    WM97+ — Boiler Manual fired water boiler DIAGNOSTIC menu DIAGNOSTICS menu navigation (see Figure 80, page 72 for access information) Figure 89 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 82 WM97+ — Boiler Manual fired water boiler DIAGNOSTICS menu (continued) DIAGNOSTICS menu details (see Figure 89, page 81 for access information) Figure 90 Menu/Item Units High Default Comment Value Value To reset all history counters to zero: Enter the DIAGNOSTICS menu. Then press and hold the left TO RESET ALL HISTORY COUNTERS TO ZERO: and right arrows located below the control display.
  • Page 83 WM97+ — Boiler Manual fired water boiler DIAGNOSTICS menu (continued) DIAGNOSTICS menu details (continued) (see Figure 89, page 81 for access information) Figure 91 Menu/Item Units High Default Comment Value Value To reset all history counters to zero: Enter the DIAGNOSTICS menu. Then press and hold the left TO RESET ALL HISTORY COUNTERS TO ZERO: and right arrows located below the control display.

  • Page 84: Maintenance, Date And Time Menus

    WM97+ — Boiler Manual fired water boiler MAINTENANCE, DATE AND TIME menus MAINTENANCE, DATE AND TIME menus — navigation (see Figure 80, page 72 for access information) Figure 92 MAINTENANCE INFO NAME ################ PHONE ###-###-#### MODEL WM97+ ### ########## INSTALLED MM/DD/YY LAST DATE MM/DD/YY...

  • Page 85: Startup - Fill The System

    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 119, page 117 for connected) to remove sediment.
  • Page 86 Weil-McLain WM97+ boilers. Do not apply these products or instructions 4. Follow instructions on antifreeze container to determine the amount for other applications.

  • Page 87: Startup - Final Checks

    WM97+ — Boiler Manual fired water boiler Startup — final checks Inspect/fill condensate system Check for gas leaks Inspect/check condensate lines and fittings 1. Inspect the condensate drain line, condensate PVC fittings and Before starting the boiler, and during initial operation, condensate trap.
  • Page 88 1. Verify boiler has been converted for propane. See page 14 for Inspect vent piping and air piping for signs of deteriora- ❏ ❏ WM97+70 or 110 or page 16 for WM97+155. tion from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.
  • Page 89 WM97+ — Boiler Manual fired water boiler Startup — final checks (continued) Operating instructions (WARNING — Verify that the WM97+ control is set for the correct boiler model before Figure 95 proceeding.) – 89 – Part number 550-142-085/0712...
  • Page 90 AUTO. DO NOT adjust throttle on low fire. 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 fire.
  • Page 91 AUTO. DO NOT adjust throttle on low fire. be leakage, follow the procedure for checking 7. Consult your local Weil-McLain representative if acceptable results the heat exchanger-to-condensate dish seal on cannot be obtained for both high and low fire.

  • Page 92: Check-Out/Startup Verification

    All instructions shipped with this boiler reviewed with owner instructions in this manual to install the propane or maintenance person? orifice bushing. See page 14 for WM97+70 or 110 or page 16 for WM97+155. Failure to comply could result in severe personal injury, death or substantial Before leaving: property damage.

  • Page 93: Annual Startup And General Maintenance

    WM97+ — Boiler Manual 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 94: Annual Startup

    Inspect the heat exchanger and clean if necessary (see page 110 from occupational sources is carci- (for WM97+70 or 110) or page 113 (for WM97+155) for access and cleaning procedures). nogenic to humans (Group 1).”: b.

  • Page 95: Address Reported Problems

    WM97+ — Boiler Manual fired water boiler Annual startup (continued) Clean condensate trap The boiler should be inspected and 1. See Figure 100. started annually, at the beginning of the heating season, only by a qualified 2. Disconnect top nut that secures the trap body to the boiler service technician.
  • Page 96 Replace with a larger tank 2. WM97+155 only — See page 41 for information. if necessary. 3. WM97+70 and 110 only — The boiler is fitted with an inte- gral diaphragm-type tank (12 liters, 3.2 gallons). The tank is Inspect ignition electrode factory charged to 12 PSIG.

  • Page 97: Check Flame Signal

    Figure 89, page 81 for the complete Diagnostics menus). tings. Adjust settings if necessary. 2. The flame signal value must be at least 75 for a WM97+70 2. Check settings of external limit controls (if any) and adjust or 110, or at least 160 for the WM97+155. If the flame signal if necessary.

  • Page 98: Check Flue Gas Temperature

    WM97+ — Boiler Manual fired water boiler Annual startup (continued) Check blower speeds Firing rates and corresponding blower speeds (low fire, Figure 102 ignition, and high fire) — for altitudes up to 5,500 feet and high altitude (above 5,500 feet) 1.

  • Page 99: Check Boiler Relief Valve

    WM97+ — Boiler Manual 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 100: Troubleshooting

    WM97+ — Boiler Manual fired water boiler Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING VERIFY PROPER OPERATION AFTER SERVICING BEFORE TROUBLESHOOTING — BEFORE TROUBLESHOOTING — Before calling for troubleshooting assistance, fill in the “ ” (page 132). WM97+ Gas Data Collection Sheet 1.

  • Page 101: Checking Temperature Sensors

    Figure 105 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.). If shown) one of these fuses is blown, it can prevent WM97+ control or other components from operating.
  • Page 102 WM97+ — Boiler Manual 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. Figure 108 shows the screen behavior 3.
  • Page 103 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Troubleshooting suggestions for WM97+ boilers — Figure 109 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 104 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Troubleshooting suggestions for WM97+ boilers — Fault displays, diagnostics and corrective actions Figure 110 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 incorrect wiring.
  • Page 105 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...
  • Page 106 WM97+ — Boiler Manual fired water boiler Troubleshooting Troubleshooting (continued) (continued) Troubleshooting suggestions for WM97+ boilers — Fault displays, diagnostics and corrective actions Figure 110 (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 limit opens.
  • Page 107 WM97+ control. Unplug connection at blower and at WM97+ control automatically restart if condition and check continuity between ends. Blower is connected to both low NOTICE: WM97+70 or 110 is corrected voltage and line voltage harness. only — The blower will not...

  • Page 108: Maintenance

    McLain distributors. Find the cartridge part number on the circulator label or in Figure 125, page 122 (WM97+70 in severe personal injury, death or substantial property or 110) or Figure 127, page 124 (WM97+155).
  • Page 109 8. Use a flashlight and mirror to insepct around the perimeter of the Inspect joints heat exchanger where it joins the condensate dish (see Figure 112 for a WM97+70 or 110 or Figure 113 for WM97+155). 9. There must be no signs of water leakage anywhere around the heat exchanger-to-condensate dish joint.

  • Page 110: Cleaning Heat Exchanger Flue Side, 70/110

    WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 70/110 Cleaning the WM97+70 or 110 heat Legend for Figure 115, page 111 Figure 114 exchanger FLUE SIDE or accessing the burner, if required Boiler interior Heat exchanger cover plate Boiler interior, with The boiler contains ceramic fiber materials.
  • Page 111 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 70/110 (continued) Accessing the burner or heat exchanger (see Legend on next page) Figure 115 – 111 – Part number 550-142-085/0712...
  • Page 112 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 70/110 (continued) e. Inspect the burner exterior. It must be in good condition, 6. Reinstall the igniter assembly (item 7). with no visible damage. a. The igniter gasket must be intact and in good condition. f.

  • Page 113: Cleaning Heat Exchanger Flue Side, 155

    WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 155 Cleaning the WM97+155 heat 6. Inspect the interior of the burner. Brush and vacuum the interior if needed to remove lint or sediment. Alternative exchanger FLUE SIDE or accessing cleaning methods: •...
  • Page 114 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 155 (continued) Inspect refractory and replace burner gasket Legend for Figure 117, page 115 Figure 116 1. See Figure 117, page 115 part D. a. Inspect the refractory to make sure it is intact, with no Boiler interior Igniter assembly visible damage.
  • Page 115 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 155 (continued) Accessing the burner or heat exchanger (see Legend on next page) Figure 117 – 115 – Part number 550-142-085/0712...

  • Page 116: Replacement Parts

    Failure to Replacement parts must be purchased through a local Weil-McLain replace damaged components and to use only the distributor. When ordering, specify boiler model and size and include parts specifically intended for the boiler can result description and part number of replacement part.
  • Page 117 2” polypropylene pipe ... . ICRT2439 3” polypropylene pipe ... . ICRT3539 Go to www.weil-mclain.com to locate Weil-McLain distributors – 117 – Part number 550-142-085/0712...
  • Page 118 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Jacket parts — WM97+70/110/155 (see Figure 121, page 119 for illustration) Figure 120 Part Number Item Name Description / contents 70 / 110 Front door Front door, seals, logo, and labels...
  • Page 119 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Jacket assembly — WM97+70/110/155 (see Figure 120, page 118 for part numbers) Figure 121 Go to www.weil-mclain.com to locate Weil-McLain distributors – 119 – Part number 550-142-085/0712...
  • Page 120 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Heat exchanger parts WM97+70/110/155 (see Figure 123, page 121 for illustration) Figure 122 WM97+70/110 WM97+155 (Figure 123, page 121) (Figure 124, page 121) Item Name Part Number Item Name Part Number...
  • Page 121 WM97+70/110 heat exchanger assembly WM97+155 heat exchanger assembly (see Figure 123 Figure 124 (see Figure 122, page 120 for part numbers) Figure 122, page 120 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 121 – Part number 550-142-085/0712...
  • Page 122 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Piping components for WM97+70/110 (see Figure 126, page 123 for illustration) Figure 125 Model Item Name Description / contents Part Number Upper water pipes Upper pipe assembly and gaskets (1 pump, 2 water)
  • Page 123 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Piping components for WM97+70/110 (see Figure 125, page 122 for part numbers) Figure 126 Go to www.weil-mclain.com to locate Weil-McLain distributors – 123 – Part number 550-142-085/0712...
  • Page 124 Shipped loose for field installation 383-000-000 Relief valve 30 PSIG relief valve — shipped loose for field installation 383-500-095 Gas flex line adapter NPT to flare adapter 562-302-571 Go to www.weil-mclain.com to locate Weil-McLain distributors – 124 – Part number 550-142-085/0712...
  • Page 125 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Piping components for WM97+155 (see Figure 125, page 122 for part numbers) Figure 128 Go to www.weil-mclain.com to locate Weil-McLain distributors – 125 – Part number 550-142-085/0712...
  • Page 126 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Controls and electrical components — WM97+70/110/155 (see Figure 130, page 127 for illustration) Figure 129 Item Name Description / contents Part Number Flue temperature sensor One sensor 511-724-292 Outdoor temperature sensor...
  • Page 127 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Controls and electrical assemblies — WM97+70/110/155 (see Figure 129, page 126 for part numbers) Figure 130 Go to www.weil-mclain.com to locate Weil-McLain distributors – 127 – Part number 550-142-085/0712...

  • Page 128: Dimensions

    WM97+ — Boiler Manual fired water boiler Dimensions Dimensional data — WM97+70/110/155 (all dimensions in inches) Figure 131 (shows field-installed components) (shows field-installed components) RIGHT RIGHT FRONT FRONT 70/110 BOTTOM BOTTOM (shows field-installed components) (shows field-installed components) Boiler supply tapping —...

  • Page 129: Ratings - Wm97+ Boilers

    AFUE are certified by AHRI. AFUE de-rate as vent/air pipe length increases, is also know as Annual Fuel Utilization WM97+70 or 110 vent/air pipes can be due to the pressure loss through the Efficiency or Seasonal Efficiency. either 2” or 3”...

  • Page 130: Ratings - Multiple Wm97+ Boilers

    12.8 Operating weight is the total weight of the 12.1 boiler, including water. 17.1 WM97+70 or 110 vent/air pipes can be either 15.1 2” or 3” pipe. 21.4 WM97+155 vent/air pipes must be 3”. 11.7 All of the boilers will automatically de-rate 18.1...

  • Page 131: Installation And Service Certificate

    WM97+ — Boiler Manual 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 132: Wm97+ Gas Boiler Data Collection Sheet

    WM97+ — Boiler Manual fired water boiler WM97+ 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: Near boiler pipe size: Top: _____ Bottom (DHW): _____ HEATING: HIGH __ LOW __ MED __OFF __...

This manual is also suitable for:

Wm97+110Wm97+155

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