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Weil-McLain WM97-70-CT Manual

Weil-McLain WM97-70-CT Manual

Gas-fired water boilers
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Matching High Performance
Companion Water Heater
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This manual must only be used by a qualified heating installer/service technician. Read all instructions, includ-
ing 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.
Gas-Fired Water Boilers
WM97+70/110/155 - CT
• Installation
• Maintenance
• Startup
• Parts
Part number 550-142-120/0113

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Summary of Contents for Weil-McLain WM97-70-CT

  • Page 1 Gas-Fired Water Boilers WM97+70/110/155 - CT Boiler Manual • Installation • Maintenance • Startup • Parts Now available Matching High Performance Companion Water Heater (Unit sold separately) This manual must only be used by a qualified heating installer/service technician. Read all instructions, includ- ing this manual and all other information shipped with the boiler, before installing.

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

    WM97+ — Boiler Manual fired water boiler The WM97+70 & 110 Gas-fired water boilers 1. Stainless steel firetube heat exchanger to match boiler output to space heating and/or DHW heating 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 550-142-120/0113...

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

    WM97+ — Boiler Manual fired water boiler The WM97+155 Gas-fired water boiler 1. Stainless steel firetube heat exchanger DHW heating demand. The control provides for three heating 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 550-142-120/0113...

  • 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 may have to be replaced when accessing or disassembling Wall-mounting the boiler parts of the boiler.

  • 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 1 for recommended service clearances. 1. See Figure 2 for REQUIRED minimum clearances. ALL installa- tion must provide at least these minimums.

  • Page 10: Wall-Mounting The Boiler

    WM97+ — Boiler Manual fired water boiler Wall-mounting the boiler Remove boiler from crate Figure 3 Boiler shipping container (WM97+70 shown) The boiler is heavy . 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 11 WM97+ — Boiler Manual fired water boiler Wall-mounting the boiler (continued) Install the wall-mount bracket and Figure 5 Place boiler on wall-mount bracket 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 pressure higher than 30 PSIG . This is the maximum allowable relief valve 70/110 models only: CLOSE the internal expansion tank setting for the WM97+ boiler.
  • Page 13 WM97+ — Boiler Manual fired water boiler Boiler hydrostatic test (continued) Figure 6 Figure 7 Install pipe fittings for relief Install piping components required for hydrostatic test valve and pressure/temperature (WM97+70/110 shown) (see legend below) gauge — DO NOT mount relief valve until AFTER hydrostatic testing (see legend at right)

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

    WM97+ — Boiler Manual fired water boiler Converting boiler to propane — WM97+70/110 Figure 8 Propane gas orifice bushing identification 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 1 1 0...
  • Page 15 WM97+ — Boiler Manual fired water boiler Converting boiler to propane — WM97+70/110 (cont.) Figure 10 Installing the propane gas orifice bushing (some details omitted for clarity) 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.) Figure 12 Installing the propane gas orifice bushing (some details omitted for clarity) Figure 13 Gas valve and venturi 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

    WM97+ — Boiler Manual fired water boiler Gas piping — sizing gas lines Boiler gas connection is ½” NPT. Size gas lines large Figure 14 Pipe capacity for 0.60 specific gravity enough to provide gas to all connected appliances. natural gas; pipe length is in equivalent feet Natural Gas: Capacity...

  • 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 137, page 133 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 123, page 119 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 INSPECTION .

  • Page 23: Vent Termination Requirements

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

  • Page 24: Boiler Room Air Openings

    WM97+ — Boiler Manual fired water boiler Boiler room air openings Figure 20 Combustion and ventilation air openings for WM97+ Direct Vent installations 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. Figure 23 Hole preparation in wall — INSIDE VIEW 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 & Figure 25 — Separate pipes sidewall 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 & Figure 28 — Concentric horizontal 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) Figure 29 Termination location — concentric See notices on previous page. 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 & Figure 31 Separate pipes vertical termination 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) Figure 32 Terminations for multiple boilers See notices on previous page. 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 & Figure 33 — Concentric vertical 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) Figure 34 Vertical termination — 3” PVC concentric See notices on previous page. — 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) Figure 36 PVC LEGEND for Figure 36 concentric termination assembly — DO NOT 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 Figure 37 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 37: Install Water Piping

    WM97+ — Boiler Manual 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 42 for suggestions the boiler interior piping from turning.
  • Page 38 WM97+ — Boiler Manual 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 Top boiler connections (internal by-pass valve OPEN) adequate flow through the WM97+ boiler.
  • Page 39 WM97+ — Boiler Manual 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 13). layouts shown in this manual.
  • Page 40 WM97+ — Boiler Manual fired water boiler Internal water piping — WM97+70 and 110 Set primary/secondary by-pass valve Figure 42 WM97+70/110 internal piping with by- 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 41: 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 42: Expansion Tank - Wm97+70 And 110

    WM97+ — Boiler Manual fired water boiler Expansion tank — WM97+70 and 110 Supplementary expansion tank, if required Figure 46 WM97+70/110 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 43: Expansion Tank - Wm97+155

    WM97+ — Boiler Manual fired water boiler Expansion tank — WM97+155 Expansion tank Figure 48 WM97+155 external expansion tank piping, diaphragm or bladder-type Figure 48 and Figure 49 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 47.

  • Page 44: System Piping

    DO NOT Weil-McLain CWH manual for piping and use direct connection if any heating loop exceeds this value.
  • Page 45 13 for information Air separator RECOMMENDED for zone (for CWH installations, refer valve systems unless other 10 Flow/check valve to the Weil-McLain CWH Pressure/temperature provision is made manual) gauge, supplied with boiler, 11 Purge/drain valves (one drain field piped...
  • Page 46 64, 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 47 Connect system circulator to CIRC 2 output. on page 64, 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 48 Refer to Field wiring, begin- ning 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 49 Refer to Field wiring, begin- ning 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 50 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 sug- gested wiring in this manual. Legend — Figure 57...
  • Page 51 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. Legend — Figure 58...
  • Page 52 1. The WM97+ control operates up to three zones (DHW plus two 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. Legend — Figure 59...
  • Page 53 1. The WM97+ control operates up to three zones (DHW plus two 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. Legend — Figure 60 information —...
  • Page 54 DHW or CWH. Refer to Field wiring, beginning on page 64, 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 55 DHW or CWH. Refer to Field wiring, beginning on page 64, 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 56: Multiple Boiler Installations

    WM97+ — Boiler Manual fired water boiler Multiple boiler installations Placing multiple boilers Figure 63 Side-to-side mounting of multiple WM97+ boilers 1. Locate multiple boilers with spacings shown in Figure 63. 2. Provide indicated clearances around boilers for access and servic- ing.
  • Page 57 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 3-inch manifold — 1400 MBH required in the controller manual.
  • Page 58 Multiple boiler installations (continued) Figure 67 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) Legend — Figure 67 The boiler internal primary/secondary by-pass valve must be CLOSED for multiple boiler installations piped as shown in this manual.
  • Page 59 (continued) Figure 68 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) The boiler internal primary/secondary by-pass valve must be CLOSED for multiple boiler installations Legend —...
  • Page 60 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 61 WM97+ — Boiler Manual fired water boiler Multiple boiler installations (continued) Figure 70 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 62: 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. – 62 – Part number 550-142-120/0113...

  • Page 63: Gas Piping

    WM97+ — Boiler Manual fired water boiler Gas piping Use two wrenches 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 14.

  • Page 64: Field Wiring

    WM97+ — Boiler Manual fired water boiler Field wiring ELECTRICAL SHOCK The installation must com- Wiring must be N.E.C. HAZARD — For your safe- ply with: Class 1. If original wiring ty, turn off electrical power as supplied with boiler must National Electrical Code supply at service entrance be replaced, use only type...
  • Page 65 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 66 WM97+ — Boiler Manual fired water boiler Field wiring (continued) Low voltage wiring (24 VAC) Figure 76 low voltage WM97+ input and output 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 76.

  • Page 67: Wiring Diagram - Schematic

    WM97+ — Boiler Manual fired water boiler Wiring diagram — schematic Figure 77 WM97+ schematic wiring diagram (see Figure 78, page 68 for legend and notes) – 67 – Part number 550-142-120/0113...

  • Page 68: Wiring Diagram - Ladder

    WM97+ — Boiler Manual fired water boiler Wiring diagram — ladder Figure 78 WM97+ ladder wiring diagram (see Figure 77, page 67 for schematic wiring diagram) – 68 – Part number 550-142-120/0113...

  • Page 69: Express Setup - Using Default Settings

    WM97+ — Boiler Manual fired water boiler EXPRESS SETUP — using default settings Figure 79 MANDATORY CONTROL SETTINGS Using default control settings ( — The No DHW CIRCULATOR-zoned systems following settings must be checked and adjusted primary/secondary piping if necessary: BOILER MODEL and HIGH AL- TITUDE in BOILER SETTINGS menu.
  • Page 70 WM97+ — Boiler Manual fired water boiler EXPRESS SETUP — using default settings (continued) Figure 80 Figure 81 Using default control settings ( Using default control settings ( 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 71: Wm97+ Control Operation

    WM97+ — Boiler Manual fired water boiler WM97+ control operation Figure 82 Control sequence of operation Temperature settings — You must ensure that the WM97+ control is set for the proper water temperatures Display Control action for the system. Excessive water temperature can cause status (also see Figure 83, page 72) significant property damage in some applications.
  • Page 72 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- Figure 83 WM97+ control display screens and typical navigation cally enables the CWH screens and CWH control operation.

  • Page 73: Essential Settings

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

  • Page 74: 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- Figure 84 WM97+ control menu access — accessing cally enables the CWH screens and CWH control operation.

  • Page 75: Boiler Settings Menus

    WM97+ — Boiler Manual fired water boiler BOILER SETTINGS menus Figure 85 BOILER SETTINGS menus (see Figure 86, page 76 for setting values and descriptions) – 75 – Part number 550-142-120/0113...
  • Page 76 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 boiler model when power is restored. Check the against the model listed on the boiler’s rating plate.

  • Page 77: Heat Settings Menus

    WM97+ — Boiler Manual fired water boiler HEAT SETTINGS menus Figure 87 HEAT SETTINGS menus (see Figure 89, page 79 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 78 WM97+ — Boiler Manual fired water boiler HEAT SETTINGS menus (continued) HEAT SETTINGS Figure 88 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 89, page 79 for a listing of menu listings.
  • Page 79 WM97+ — Boiler Manual 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 80: 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 Figure 90 DHW SETTINGS menus (see Figure 91, page 81 for CWH screens and CWH control operation.
  • Page 81 WM97+ — Boiler Manual fired water boiler DHW SETTINGS menus (continued) TEMPERATURES (DHW) CWH Installations — See Companion Water Heater manual for control settings information. DHW priority — The WM97+ control gives priority to DHW operation. During DHW call for heat, the TIMES (DHW TIMES) space heating zone ouputs (Zone 2 and Zone 3) are disabled.

  • Page 82: Circulator Exercising And Freeze Protection Circulators Menus

    WM97+ — Boiler Manual fired water boiler CIRCULATOR EXERCISING and FREEZE PROTECTION CIRCULATORS menus Figure 92 CIRCULATOR (SYSTEM SETTINGS) menu navigation (see Figure 84, page 74 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 83: Diagnostic Menu

    WM97+ — Boiler Manual fired water boiler DIAGNOSTIC menu Figure 93 DIAGNOSTICS menu navigation (see Figure 84, page 74 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 84 WM97+ — Boiler Manual fired water boiler DIAGNOSTICS menu (continued) Figure 94 DIAGNOSTICS menu details (see Figure 93, page 83 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 85 WM97+ — Boiler Manual fired water boiler DIAGNOSTICS menu (continued) Figure 95 DIAGNOSTICS menu details (continued) (see Figure 93, page 83 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 86: Maintenance, Date And Time Menus

    WM97+ — Boiler Manual fired water boiler MAINTENANCE, DATE AND TIME menus Figure 96 MAINTENANCE, DATE AND TIME menus — navigation (see Figure 84, page 74 for access information) MAINTENANCE INFO NAME ################ PHONE ###-###-#### MODEL WM97+ ### ########## INSTALLED MM/DD/YY LAST DATE MM/DD/YY...

  • Page 87: 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 123, page 119 for connected) to remove sediment.
  • Page 88 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 89: 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 90 WM97+ — Boiler Manual fired water boiler Startup — final checks (continued) Final checks before starting boiler ❏ Check gas piping 1. Check around the boiler and inside the boiler jacket for gas Read the instructions to adjust and set up the WM97+ ❏...
  • Page 91 WM97+ — Boiler Manual fired water boiler Startup — final checks (continued) Figure 99 Operating instructions (WARNING — Verify that the WM97+ control is set for the correct boiler model before proceeding.) – 91 – Part number 550-142-120/0113...
  • Page 92 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 93 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 94: Check-Out/Startup Verification

    WM97+ — Boiler Manual fired water boiler Check-out/startup verification Adjust and test boiler controls WM97+ control operation for space heating and DHW (if ❏ ❏ used) verified per this manual? 1. Follow instructions in this manual to set and verify operation of the boiler controls.

  • Page 95: 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 96: Annual Startup

    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 may be needed are available .
  • Page 97 WM97+ — Boiler Manual fired water boiler Annual startup (continued) Clean condensate trap The boiler should be inspected and 1. See Figure 104. 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 98 WM97+ — Boiler Manual fired water boiler Annual startup (continued) Check air openings • Do not use automatic air vents in systems with closed- 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 99 6. Inspect the flame at high and low fire. If flame is still not ac- ceptable, check combustion values. If combustion is properly 1. Inspect all boiler wiring, making sure wires are in good condi- adjusted, obtain a replacement burner from Weil-McLain. tion and securely attached. 2. Verify that all connectors are securely inserted.
  • Page 100 WM97+ — Boiler Manual fired water boiler Annual startup (continued) Check blower speeds Figure 106 Firing rates and corresponding blower speeds (low fire, ignition, and high fire) — for altitudes up to 5,500 feet and high altitude (above 5,500 feet) 1.
  • Page 101 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 102: 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 WM97+ Gas Data Collection Sheet “ ” (page 136). 1.
  • Page 103 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Check WM97+ control fuses Figure 109 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 104 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 112 shows the screen behavior 3.
  • Page 105 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Figure 113 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 106 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Figure 114 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 incorrect wiring.
  • Page 107 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 108 WM97+ — Boiler Manual fired water boiler Troubleshooting Troubleshooting (continued) (continued) Figure 114 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 limit opens.
  • Page 109 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Figure 114 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 110: Internal Water Piping - Wm97+70 And

    WM97+ — Boiler Manual fired water boiler Maintenance Boiler circulator repair DO NOT SERVICE THE BOILER WITHOUT A WM97+ Circulator cartridge replacement MAINTENANCE KIT AVAILABLE 1. The circulator supplied with the boiler is a water-lubricated, cartridge-type circulator. If the circulator fails, try replac- The WM97+ maintenance kit includes components that ing the circulator cartridge instead of replacing the entire may have to be replaced when accessing or disassembling...
  • Page 111 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- Funnel tions supplied with the cleaner to clean the boiler heat exchanger. Use ONLY the cleaning product available from Weil- Control housing McLain, Sentinel X400.

  • Page 112: 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 Figure 118 Legend for Figure 119, page 113 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 113 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 70/110 (continued) Figure 119 Accessing the burner or heat exchanger (see Legend on next page) – 113 – Part number 550-142-120/0113...
  • Page 114 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 70/110 (continued) • swirl the burner thoroughly in a bucket of mild liquid Before handling the assembly, allow the adhesive to set laundry detergent water, then rinse thoroughly. enough that the refractory is firmly held in place.
  • Page 115 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 155 Cleaning the WM97+155 heat • clean with a water spray from inside the burner; • swirl the burner thoroughly in a bucket of mild liquid laundry deter- exchanger FLUE SIDE or accessing gent water, then rinse thoroughly.
  • Page 116 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 155 (continued) Inspect refractory and replace burner gasket Figure 120 Legend for Figure 121, page 117 1. See Figure 121, page 117 part D. a. Inspect the refractory to make sure it is intact, with no Boiler interior Air silencer clip visible damage.
  • Page 117 WM97+ — Boiler Manual fired water boiler Cleaning heat exchanger flue side, 155 (continued) Figure 121 Accessing the burner or heat exchanger (see Legend on next page) – 117 – Part number 550-142-120/0113...

  • Page 118: 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 119 2” polypropylene pipe ... . ICRT2439 3” polypropylene pipe ... . ICRT3539 Go to www.weil-mclain.com to locate Weil-McLain distributors – 119 – Part number 550-142-120/0113...
  • Page 120 Jacket access panel, gasket (item 250) and screws 383-700-204 383-700-201 Bottom access panel gasket Gasket only 590-318-059 CWH wire harness opening plugs (not shown) One plug 561-444-190 561-444-190 Go to www.weil-mclain.com to locate Weil-McLain distributors – 120 – Part number 550-142-120/0113...
  • Page 121 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 125 Jacket assembly — WM97+70/110/155 (see Figure 124, page 120 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 121 – Part number 550-142-120/0113...
  • Page 122 Burner, gasket, and hardware (includes item 250) 383-700-106 Burner gasket 383-700-107 Heat exchanger water temperature sensor (one sensor for either boiler inlet or outlet water temperature) 511-724-296 Go to www.weil-mclain.com to locate Weil-McLain distributors – 122 – Part number 550-142-120/0113...
  • Page 123 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 127 WM97+70/110 heat exchanger assembly (see Figure 126, page 122 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 123 – Part number 550-142-120/0113...
  • Page 124 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 128 Heat exchanger parts WM97+155 (see Figure 129, page 125 for illustration) Item Name Part Number Heat exchanger 383-700-197 Heat exchanger with condensate dish, assembled (includes items 100, 160, 170 and 180) 383-700-198 Heat exchanger, condensate dish, cover plate, burner, igniter, sight glass, refractory, water sensors, gaskets, silicone, and hardware...
  • Page 125 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 129 WM97+155 heat exchanger assembly (see Figure 128, page 124 for part numbers) – 125 – Part number 550-142-120/0113...
  • Page 126 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 571-100-006 Go to www.weil-mclain.com to locate Weil-McLain distributors – 126 – Part number 550-142-120/0113...
  • Page 127 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 131 Piping components for WM97+70/110 (see Figure 130, page 126 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 127 – Part number 550-142-120/0113...
  • Page 128 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 – 128 – Part number 550-142-120/0113...
  • Page 129 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 133 Piping components for WM97+155 (see Figure 132, page 128 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 129 – Part number 550-142-120/0113...
  • Page 130 F2 - 12 amp, slow-blow ag (5 fuses) 5 Fuses 383-500-604 (not shown here — see Figure 111, page 103) Ground wire (not shown) Wire harness ground, igniter to jacket 591-391-991 Go to www.weil-mclain.com to locate Weil-McLain distributors – 130 – Part number 550-142-120/0113...
  • Page 131 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 135 Controls and electrical assemblies — WM97+70/110/155 (see Figure 134, page 130 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors – 131 – Part number 550-142-120/0113...

  • Page 132: Dimensions

    WM97+ — Boiler Manual fired water boiler Dimensions Figure 136 Dimensional data — WM97+70/110/155 (all dimensions in inches) (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 — shipped loose for field installation) line (if DHW tank is connected directly to the 1”...

  • Page 133: Ratings - Wm97+ Boilers

    155-CT 143,000 155,000 95.1 3” PVC Notes As an Energy Star Partner, Weil-McLain for the requirements of the building All vent and air pipe elbows must has determined that WM97+ boilers and nothing need be added for normal be sweep elbows, NOT short-radius meet the Energy Star guidelines for piping and pickup.

  • Page 134: Ratings - Multiple Wm97+ Boilers

    Net I=B=R ratings are based on piping and 110 155 pickup allowance of 1.15. Note 1 Note 2 Figure 64, page 56 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 12.1...

  • Page 135: 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 136: 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:

Wm97-110-ctWm97-155-ct

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