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Weil-McLain WM97+ Manual

Gas-fired water boilers
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See also: User's Information Manual
Boiler Manual
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-FiredWater Boilers
• Installation
• Maintenance
• Startup
• Parts
Part number 550-142-058/0811

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Summary of Contents for Weil-McLain WM97+

  • Page 1 Gas-FiredWater Boilers Boiler Manual • Installation • Maintenance • Startup • Parts 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.

  • Page 2: The Wm97+ Gas-Fired Water Boiler

    WM97+ — Boiler Manual fired water boiler The WM97+ Gas-fired water boiler 1. Stainless steel firetube heat exchanger or 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 3 WM97+ — Boiler Manual fired water boiler The WM97+ Gas-fired water boiler (continued) Part number 550-142-058/0811...

  • Page 4: Table Of Contents

    WM97+ — Boiler Manual fired water boiler Contents The WM97+ Gas-fired water boiler DO NOT SERVICE THE Please read before proceeding BOILER WITHOUT A WM97+ 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 5: Please Read Before Proceeding

    WM97+ — Boiler Manual fired water boiler Please read before proceeding Hazard definitions • Should overheating occur or gas supply fail to shut off, DO NOT turn off or disconnect The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels electrical supply to circulator.

  • Page 6: Boiler Location

    WM97+ — Boiler Manual fired water boiler Boiler location Installations must comply with: • Locate or protect the boiler so it cannot be damaged by a moving vehicle. • Local, state, provincial, and national codes, laws, regulations • Ensure that the installation complies with all applicable and ordinances.

  • Page 7: Prepare Boiler Location

    WM97+ — Boiler Manual fired water boiler Prepare 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 8: Wall-Mounting The Boiler

    Figure 4 Wall-mount bracket and spacer board The operating weights for wall-mountable boilers are: 140 pounds WM97+70 or WM97+110: Failure to comply with above and the procedure given below could result in severe personal injury, death or substantial property damage.
  • Page 9 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 8. 2. Locate the studs — must be on 16-inch centers. See previous page instructions if studs are not on 16-inch centers.

  • Page 10: Boiler Hydrostatic Test

    WM97+ — Boiler Manual fired water boiler Boiler hydrostatic test DO NOT install a relief valve with a pressure higher Figure 6 Install pipe fittings for relief valve and than 30 PSIG . This is the maximum allowable relief pressure/temperature gauge (DO NOT valve setting for the WM97+ boiler.
  • Page 11 WM97+ — Boiler Manual fired water boiler Boiler hydrostatic test (continued) 3. CLOSE boiler drain valve (item 16). Connect a hose to fresh water Figure 7 Install piping components required for supply and to the drain valve. hydrostatic test 4. Place a bucket under the ends of pipe nipples, item 15 and item 17, to catch water drippage.

  • Page 12: Converting Boiler To Propane

    Converting boiler to propane Figure 8 Propane gas orifice bushing identification Prepare boiler for propane WM97+70 on left (may be stamped 3.85) (when required) WM97+110 on right (may be stamped 4.45) Propane operation ALL WM97+ boilers must be converted for...
  • Page 13 WM97+ — Boiler Manual fired water boiler Converting boiler to propane (continued) Figure 10 Installing the propane gas orifice bushing (some details omitted for clarity) 7. Insert the propane gas orifice bushing into the gas valve outlet (see Figure 10). LEGEND for Figure 10 8.

  • Page 14: Gas Piping - Sizing Gas Lines

    1650 b. Minimum gas pressure, with gas flowing (verify during boiler 1400 startup, while boiler is at high fire) — WM97+70: 3½” (89 mm) w.c.; WM97+110: 4½” (114 mm) w.c. 1130 2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 13”...

  • Page 15: 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 16 When using 2” pipe, provide 3”x2” reducers at boiler connections and at Weil-McLain vent/air cap or at concentric terminations. Boilers using 2” pipe will derate as vent/air pipe length increases — allow up to 10% for the WM97+70 or 15% for the WM97+110.
  • Page 17 Dura-Vent — FasNSeal™ steel Metal-Fab, Inc. — CORR/GUARD Weil-McLain stainless steel bird screens, 2” or 3” (purchase separately) — see Figure 93, page 95 for part numbers Note 1: Weil-McLain concentric vent kits are made from PVC ADAPTERS — AL29-4C piping — Install a PVC-to- stainless adapter supplied by the AL29-4C stainless pipe pipe and fittings.

  • Page 18: 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. INSPECTION (a) For all sidewall horizontally-vented gas-fueled equipment .

  • Page 19: Vent Termination Requirements

    WM97+ — Boiler Manual fired water boiler Vent termination requirements Figure 16 The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). For Canadian installations, defer to the requirements of CSA B149.1 or B149.2 Installation Code. Part number 550-142-058/0811...

  • Page 20: Boiler Room Air Openings

    WM97+ — Boiler Manual fired water boiler Boiler room air openings Figure 17 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 7.

  • Page 21: 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 22 Level the template with a level. (use template provided) For the Weil-McLain plate, the template must be level to ensure the flue and air pipe will be side-to-side, as shown in Figure 19. Failure to comply could result in severe personal injury, death or substantial property damage.

  • Page 23: Direct Vent - Sidewall With Separate Pipes

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Sidewall with separate pipes Allowable vent/air pipe materials & Figure 22 — Separate pipes sidewall INSTALLATION SEQUENCE lengths Use only the vent materials and kits listed in Figure 15, page 17. Provide pipe adapters if specified.

  • Page 24: Prepare Wall Penetrations

    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 25: Direct Vent - Sidewall Concentric

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Sidewall concentric Allowable vent/air pipe materials & Figure 25 — Concentric horizontal INSTALLATION SEQUENCE lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 15, page 17.
  • Page 26 WM97+ — Boiler Manual fired water boiler DIRECT VENT — Sidewall concentric (continued) Figure 26 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 27: Direct Vent - Vertical With Separate Pipes

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical with separate pipes Allowable vent/air pipe materials & Figure 28 Separate pipes vertical termination lengths Use only the vent materials and kits listed in Figure 15, page 17. Provide pipe adapt- ers if specified.

  • Page 28: Prepare Roof Penetrations

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical with separate pipes (continued) Figure 29 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 29: Direct Vent - Vertical Concentric

    WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical concentric Allowable vent/air pipe materials & Figure 30 — Concentric vertical INSTALLATION SEQUENCE lengths 1. The concentric termination kit must be purchased separately. Use only the vent materials and kits listed in Figure 15, page 17.
  • Page 30 WM97+ — Boiler Manual fired water boiler DIRECT VENT — Vertical concentric (continued) Figure 31 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 31: Concentric Termination, Typical (Sidewall Or Vertical)

    WM97+ — Boiler Manual fired water boiler Concentric termination, typical (sidewall or vertical) LEGEND for Figure 33 Figure 33 PVC concentric termination assembly — DO NOT attach the rain cap until the termination has been 1 — Inner PVC pipe (vent) 4 —...

  • Page 32: Vent And Air Piping And Boiler Connections

    WM97+ — Boiler Manual fired water boiler Vent and air piping and boiler connections Follow termination instructions Figure 34 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 33: Install Water Piping

    WM97+ — Boiler Manual fired water boiler Install water piping Install relief valve Use two wrenches when tightening water piping at boiler, using one of the wrenches to prevent the boiler interior 1. Install relief valve in ¾” street elbow piped from boiler piping from turning.
  • Page 34 WM97+ — Boiler Manual fired water boiler Install water piping (continued) Set primary/secondary by-pass valve Figure 35 Internal piping with by-pass valve closed (boiler circulator provides system flow) 1. The primary/secondary by-pass valve (item 7 in the illustrations — details and jacket removed for clarity — at right) allows selecting whether the boiler is direct-connected or see legend below left primary/secondary connected to the system.
  • Page 35 WM97+ — Boiler Manual fired water boiler Install water piping (continued) Supplementary expansion tank, if required Figure 37 External expansion tank piping, — systems having volumes more than diaphragm or bladder-type 15 gallons only 1. The boiler is equipped with an internal diaphragm-type expansion tank, factory charged to 12 PSIG.

  • Page 36: Verify The Application Will Work

    WM97+ — Boiler Manual fired water boiler Install water piping (continued) ZONE VALVE zoning — direct connection Figure 39 Zone valve zoning — direct connection (primary/secondary by-pass valve (boiler circulator provides flow for system — boiler primary/secondary by-pass valve CLOSED) CLOSED) (See next page for legend) The boiler internal circulator can be used to circulate many heat- ing systems using the arrangement shown in Figure 39 and in Fig-...
  • Page 37 Zone valve zoning — direct connection (boiler Figure 41 The system must meet the following primary/secondary by-pass valve CLOSED) requirements when applying Figure 40 Boiler model WM97+70 WM97+110 MAIN line size (inches) BRANCH line size ¾ ¾ (inches) [ Total FLOW, GPM...
  • Page 38 The control module zone output circuits are all 120 VAC. ZONE VALVES must be 120-volt, 4-wire b. For more than 3 zones, use a Weil-McLain WMZV zone con- or must be operated by relays with 120-VAC coils or troller. See suggested wiring in this manual.
  • Page 39 WM97+ — Boiler Manual fired water boiler Install water piping (continued) CIRCULATOR zoning — primary/ Figure 43 Circulator zoning plus optional DHW secondary connection piping (primary/secondary by-pass valve OPEN) The boiler primary/secondary by-pass valve MUST be open to prevent excessive head caused by running the boiler circulator and zone circulators in series.
  • Page 40 WM97+ — Boiler Manual fired water boiler Install water piping (continued) RADIANT HEATING — CIRCULATOR Figure 44 Typical radiant heating system piping — zoning — primary/secondary boiler circulator zoning connection (primary/secondary by-pass valve OPEN) 1. The WM97+ boiler is ideal for use in radiant heating. The WM97+ boiler’s unique heat exchanger design allows it to work well even in condensing mode.
  • Page 41 2 space heating). Refer to Field wiring, beginning on page 45, for instructions on wiring to circulators. b. For more than 3 zones (including DHW), use a Weil-McLain WMCR zone controller. See suggested wiring in this manual. Legend — Figure 45 connection, when used —...
  • Page 42 WM97+ — Boiler Manual fired water boiler Install water piping (continued) WATER CHILLER systems — ZONE VALVE Figure 46 Chilled water system plus optional DHW zoning — primary/secondary boiler piping connection (primary/secondary by-pass valve OPEN) 1. Install boiler so that chilled medium is piped in parallel with the heating boiler.

  • Page 43: Install Condensate Line

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

  • Page 44: Gas Piping

    Minimum gas pressure, with gas flowing (verify Gas pipe sizing during boiler startup, while boiler is at high fire) — WM97+70: 3½” (89 mm) w.c.; WM97+110: 4½” 1. See page 14 for gas line sizing information. (114 mm) w.c.

  • Page 45: 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 46 WM97+ — Boiler Manual fired water boiler Field wiring (continued) Line voltage wiring (120 VAC) Figure 51 WM97+ line voltage input and output connections (120 VAC) Make the following line-voltage connections, some of which depend on your system and how the WM97+ control module will be programmed. The callouts below refer to Figure 51.
  • Page 47 WM97+ — Boiler Manual fired water boiler Field wiring (continued) Low voltage wiring (24 VAC) Figure 52 WM97+ low voltage input and output connections (24 VAC) Make the following low-voltage connections, some of which depend on your system and how the WM97+ control module will be programmed. The callouts below refer to Figure 52.

  • Page 48: Wiring Diagram - Schematic

    WM97+ — Boiler Manual fired water boiler Wiring diagram — schematic Figure 53 WM97+ schematic wiring diagram (see Figure 54, page 49 for legend and notes) Part number 550-142-058/0811...

  • Page 49: Wiring Diagram - Ladder

    WM97+ — Boiler Manual fired water boiler Wiring diagram — ladder Figure 54 WM97+ ladder wiring diagram (see Figure 53, page 48 for schematic wiring diagram) Part number 550-142-058/0811...

  • Page 50: Express Setup - Using Default Settings

    WM97+ — Boiler Manual fired water boiler EXPRESS SETUP — using default settings MANDATORY CONTROL SETTINGS Figure 55 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 51 WM97+ — Boiler Manual fired water boiler EXPRESS SETUP — using default settings (continued) Figure 56 Using default control settings ( Figure 57 Using default control settings ( No DHW No DHW ZONE VALVE-zoned systems ZONE VALVE-zoned systems direct connection piping primary/secondary piping Legend and guidelines —...

  • Page 52: Control Module Operation

    WM97+ — Boiler Manual fired water boiler Control module operation Figure 58 Control sequence of operation Temperature settings — You must ensure that the control module is set for the proper water temperatures Display Control action for the system. Excessive water temperature can cause status (also see Figure 59, page 53) significant property damage in some applications.
  • Page 53 WM97+ — Boiler Manual fired water boiler Control module operation (continued) Figure 59 Control module display screens and typical navigation (see Figure 63, page 58) Part number 550-142-058/0811...

  • Page 54: 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 55: Control Module Settings

    WM97+ — Boiler Manual fired water boiler Control module settings Figure 60 WM97+ control module menu access — accessing contractor menus BEFORE PROCEEDING, perform essential 5. The CONTRACTOR MENU screen will show: control settings as instructed on page 54. a. BOILER SETTINGS — see page 56 for details Control menus —...

  • Page 56: Boiler Settings Menus

    WM97+ — Boiler Manual fired water boiler BOILER SETTINGS menus Figure 61 BOILER SETTINGS menus (see Figure 62, page 57 for setting values and descriptions) Part number 550-142-058/0811...

  • Page 57: Boiler Model

    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 58: Heat Settings Menus

    WM97+ — Boiler Manual fired water boiler HEAT SETTINGS menus Figure 63 HEAT SETTINGS menus (see Figure 62, page 57 for setting values and descriptions) See table below for system type explanations Speed settings — See page 80 for blower speed adjustment procedure and acceptable speeds.
  • Page 59 WM97+ — Boiler Manual fired water boiler HEAT SETTINGS menus (continued) HEAT SETTINGS Figure 64 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. 2.
  • Page 60 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 when HIGH ALTITUDE is selected in WM97+110 1400...

  • Page 61: Dhw Settings Menus

    WM97+ — Boiler Manual fired water boiler DHW SETTINGS menus Figure 66 DHW SETTINGS menus (see Figure 62, page 57 for setting values and descriptions) DHW SETTINGS BOILER CIRCULATOR SPEED 1. The DHW SETTINGS menus are for setting control Direct-connected DHW (bottom connections) operation during DHW operation.
  • Page 62 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 when HIGH ALTITUDE is selected in WM97+110 1400...

  • Page 63: Circulator Exercising And

    WM97+ — Boiler Manual fired water boiler CIRCULATOR EXERCISING and FREEZE PROTECTION CIRCULATORS menus Figure 68 CIRCULATOR (SYSTEM SETTINGS) menu navigation (see Figure 60, page 55 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 64: Diagnostic Menu

    WM97+ — Boiler Manual fired water boiler DIAGNOSTIC menu Figure 69 DIAGNOSTICS menu navigation (see Figure 60, page 55 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 65 WM97+ — Boiler Manual fired water boiler DIAGNOSTICS menu (continued) Figure 70 DIAGNOSTICS menu details (see Figure 69, page 64 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 66 WM97+ — Boiler Manual fired water boiler DIAGNOSTICS menu (continued) Figure 71 DIAGNOSTICS menu details (continued) (see Figure 69, page 64 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 67: Maintenance, Date And Time Menus

    WM97+ — Boiler Manual fired water boiler MAINTENANCE, DATE AND TIME menus Figure 72 MAINTENANCE, DATE AND TIME menus — navigation (see Figure 60, page 55 for access information) MAINTENANCE INFO NAME ################ PHONE ###-###-#### MODEL WM97+ ### ########## INSTALLED MM/DD/YY LAST DATE MM/DD/YY...

  • Page 68: 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. A list of approved antifreeze connected) to remove sediment.
  • Page 69 9. If purge valves are not installed in system, open manual air vents in freeze-prevention fluids recommended system one at a time, beginning with lowest floor. Close vent when by Weil-McLain for application in water squirts out. Repeat with remaining vents. WM97+ Boiler systems.

  • Page 70: Startup - Final Checks

    WM97+ — Boiler Manual fired water boiler Startup — final checks Fill condensate trap with water Check for gas leaks 1. Loosen the top nut that secures the condensate trap body to the boiler condensate connection (see Figure 74). Pull the trap down to disengage from heat exchanger.
  • Page 71 1. Check around the boiler and inside the boiler jacket for gas lem, then shut down the boiler and contact odor following the procedure of page 44 of this manual. your local Weil-McLain representative. Throttle screw adjustment must be done If you discover evidence of any gas leak, shut down only by a qualified technician, using cali- the boiler at once.
  • Page 72 WM97+ — Boiler Manual fired water boiler Startup — final checks (continued) Figure 75 Operating instructions (WARNING — Verify that the control module is set for the correct boiler model before proceeding.) Part number 550-142-058/0811...
  • Page 73 DO NOT attempt an adjustment of the throttle screw at low fire. Just check the combustion values. 6. Consult your local Weil-McLain representative if ac- 4. Use the control module display to navigate to Manual test mode ceptable results cannot be obtained for both high and (see Figure 69, page 64).

  • Page 74: Check-Out/Startup Verification

    WM97+ — Boiler Manual fired water boiler Check-out/startup verification Have the following been done? ❏ ❏ Additional field-installed controls tested as outlined by control manufacturers? (Boiler should be operating and should go off when controls are tested. Verify controls cause ❏...

  • Page 75: 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 76: Annual Startup

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

  • Page 77: Address Reported Problems

    WM97+ — Boiler Manual fired water boiler Annual startup (continued) Clean condensate trap The boiler should be inspected and 1. See Figure 79. 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 78 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 79: Check Flame Signal

    1. Check ignition cable electrical resistance. A good cable will have is properly adjusted, obtain a replacement burner from resistance between 900 and 1100 ohms. Replace if not acceptable. Weil-McLain. 2. Inspect boiler ground wire from heat exchanger access cover to ground terminal screw.

  • Page 80: Check Flue Gas Temperature

    WM97+ — Boiler Manual fired water boiler Annual startup (continued) Check blower speeds Figure 81 Firing rates and corresponding blower speeds (low fire, ignition, and high fire) 1. For installations at altitudes above 5,500 feet, make sure the control — for altitudes up to 5,500 feet and high is set up for high altitude in the boiler setup menu.

  • Page 81: 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 82: Troubleshooting

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

  • Page 83: Checking Temperature Sensors

    WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Check control module fuses Figure 84 Control housing lifted to slot 2 (jacket door removed and inlet air silencer ALWAYS check control module fuses before replacing control rotated out of the way) module or any major components (blower, etc.).
  • Page 84 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. Control module fault indications 1. The control module provides diagnostic information for both manual reset condition.
  • Page 85 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Figure 88 Troubleshooting suggestions for WM97+ boilers — Control module Error Condition Log The control module 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 86 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Figure 89 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 87 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 when internal low Automatic reset occurs if Check for low water condition in system. Repair system as necessary...
  • Page 88 WM97+ — Boiler Manual fired water boiler Troubleshooting Troubleshooting (continued) (continued) Figure 88 Troubleshooting suggestions for WM97+ boilers — Fault displays, diagnostics and corrective actions (cont.) Condition Diagnostics Corrective Action(s) Display Occurs when display Automatically resets when Check for a loose connection at the molex plug on the control and DISPLAY COMM communications out for 30 communication is re-...
  • Page 89 WM97+ — Boiler Manual fired water boiler Troubleshooting (continued) Figure 88 Troubleshooting suggestions for WM97+ boilers — Fault displays, diagnostics and corrective actions (cont.) Condition Diagnostics Corrective Action(s) Display Blower unable to reach Reset using manual reset screen Check wire harness for loose connections and pin engagement at blower BLOWER FAULT required speed or does not on display;...

  • Page 90: Maintenance

    See the correct cartridge part number in Figure 98, page 100 and on circulator label. Cartridges are available 2. Check other circulators in the system. Oil any circula- from Weil-McLain and their distributors. tors requiring oil, following circulator manufacturer’s 3. Isolate and drain the boiler instructions.

  • Page 91: Tools Required

    WM97+ — Boiler Manual fired water boiler Maintenance (continued) Cleaning the heat exchanger FLUE Be careful when handling the igniter not to damage the igniter ceramic. SIDE or accessing the burner, when k. Clean the igniter if necessary. Discard and replace the required igniter if it is damaged or cannot be cleaned.
  • Page 92 WM97+ — Boiler Manual fired water boiler Maintenance (continued) Figure 90 Accessing the burner or heat exchanger (see Legend on next page) Part number 550-142-058/0811...
  • Page 93 1. Isolate the boiler from the heating system. sediment. Collect water in the bucket below. 2. Obtain Sentinel X400 cleaner from Weil-McLain. Follow 6. Inspect the heat exchanger cover plate insulation. Replace if instructions supplied with the cleaner to clean the boiler insulation is damaged.

  • Page 94: Replacement Parts

    The WM97+ maintenance kit includes compo- WEIL-McLAIN nents that may have to be replaced when access- Replacement parts must be purchased through a local Weil-McLain ing or disassembling parts of the boiler. Failure distributor. When ordering, specify boiler model and size and include to replace damaged components and to use only description and part number of replacement part.
  • Page 95 2” polypropylene pipe ... . 2PPS-HTP 3” polypropylene pipe ... . 3PPS-HTP Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...
  • Page 96 Gasket - flue adapter to cabinet 590-300-031 Gasket - pipe adapter to system pipe Gasket fits inner diameter of top adapter 590-318-052 Front door to display seal One seal (attached to control housing) 590-300-025 Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...
  • Page 97 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 95 Jacket assembly (see Figure 94, page 96 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...
  • Page 98 Spark suppressor for igniter 590-318-008 Burner Burner, gasket, and hardware 383-700-106 Burner gasket Burner gasket 383-700-107 Heat exchanger water One sensor (boiler inlet or outlet water temperature) 511-724-296 temperature sensor Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...
  • Page 99 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 97 Heat exchanger assembly (see Figure 96, page 98 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...
  • Page 100 590-300-027 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 Part number 550-142-058/0811...
  • Page 101 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 99 Piping assemblies (see Figure 98, page 100 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...
  • Page 102 383-500-603 (not shown here — see Figure 86, page 83) F2 - 12 amp, slow-blow ag (5 fuses) 5 Fuses 383-500-604 (not shown here — see Figure 86, page 83) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...
  • Page 103 WM97+ — Boiler Manual fired water boiler Replacement parts (continued) Figure 101 Controls and electrical assemblies (see Figure 100, page 102 for part numbers) Go to www.weil-mclain.com to locate Weil-McLain distributors Part number 550-142-058/0811...

  • Page 104: Dimensions

    WM97+ — Boiler Manual fired water boiler Dimensions Figure 102 Dimensional data (all dimensions in inches) LEGEND Boiler supply tapping, 1” NPT. Boiler return tapping, 1” NPT. Control panel, with display and naviga- tion buttons Electrical entrance openings Vent connection: 3” PVC Pressure/temperature gauge (shipped loosed) (shows field-installed components)

  • Page 105: Ratings - Wm97+ Boilers

    3” Notes As an Energy Star Partner, Weil-McLain has determined that WM97+ boilers meet the Energy Star guidelines for energy efficiency. NOTE: Adjusting boiler firing rate will affect AFUE rating. Based on standard test procedures prescribed by the United States Department of Energy. Ratings also referred to as CSA Output. NOTE that only DOE Heating Capacity and AFUE are certified by AHRI.

  • Page 106: Installation And Service Certificate

    WM97+ — Boiler Manual fired water boiler Installation and Service Certificate Boiler Model Series CP Number Date Installed BTU Input ❏ ❏❏❏Installation instructions have been followed. ❏ ❏ ❏ ❏ ❏ ❏❏❏Check-out sequence has been performed. ❏ ❏ ❏ ❏ ❏...

  • Page 107: 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 __ Boiler circulator speed:...
  • Page 108 WM97+ — Boiler Manual fired water boiler...

This manual is also suitable for:

Wm97+70Wm97+110

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