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Weil-McLain WM97+ Product Manual

Weil-McLain WM97+ Product Manual

Companion water heater for wm97+ gas-fired boilers
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Download this manual See also: User's Information Manual, Manual
Product Manual
High Performance
Companion Water Heater
(Boiler 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. Perform steps in the order
given. Failure to comply could result in severe personal injury, death or substantial property damage.
Companion
Water Heater
for WM97+ Gas-Fired Boilers
• Installation
• Maintenance
• Startup
• Parts
Part number 635-500-156/0113

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Summary of Contents for Weil-McLain WM97+

  • Page 1 ® Companion Water Heater for WM97+ Gas-Fired Boilers Product Manual • Installation • Maintenance • Startup • Parts High Performance Companion Water Heater (Boiler 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: Table Of Contents

    — Product Manual companion water heater Contents Page Page WM97+ Boiler with Companion Water Heater (CWH) Boiler/CWH piping — 155 / Right-side mixing valve WM97+ Boiler ......3 CONNECTIONS TO BOILER AND SYSTEM .

  • Page 3: Wm97+ Boiler With Companion Water Heater (Cwh)

    — Product Manual companion water heater WM97+ Boiler with Companion Water Heater (CWH) WM97+ Boiler Installation summary Follow the boiler manual, this manual, and all applicable codes. Installation consists of the following: • Mount boiler on the wall. • Mount boiler at height shown in the boiler WM97+ manual and make sure clearance is provided on right or left side for piping as directed.

  • Page 4: Please Read Before Proceeding

    — Product Manual companion water heater Please read before proceeding Hazard definitions Failure to adhere to the guidelines on this page can result in severe personal injury, death or substantial The following defined terms are used throughout this property damage. manual to bring attention to the presence of hazards Read all instructions before installing.

  • Page 5: Pre-Installation

    — Product Manual companion water heater Pre-installation The 18-inch mixing valve side clearance below is MANDATORY . The 1½” clearance on the opposite side is strongly recommended Codes (a smaller clearance will make servicing more difficult). ADDITIONAL clearance may be 1.

  • Page 6: Domestic Water Piping Requirements

    — Product Manual companion water heater Pre-installation (continued) Domestic water piping requirements 1. Install unions on all piping for easy removal of water heater. dielectric unions or couplings 2. Use to protect hot and cold water fittings from corrosion when connecting dissimilar materials such as copper and galvanized iron pipe.

  • Page 7: Cwh Mixing Valve

    — Product Manual companion water heater CWH Mixing valve The mixing valve assembly shown below DANGER and in the piping diagrams throughout this manual are for the Honeywell AMX302TLF. Mixing valve must be installed Figure 4 Mixing valve assembly, CWH connections Follow all instructions in this manual and in the mix- on right side ing valve manufacturer’s literature provided with the...

  • Page 8: Domestic Water Piping

    100 feet. Figure 6 DHW piping (shown with WM97+155, right-side piping, with Honeywell AMX302TLF mixing valve assembly) Part number 635-500-156/0113...
  • Page 9 CWH) • Must not be plugged, reduced or restricted or terminated with a threaded end. WM97+ boiler — Model WM97+70, 110 or 155 (155 shown) • Must not be subjected to freezing. Domestic water cold inlet Do not install any valve between the T&P relief DHW mixed outlet from mixing valve valve and CWH connection, or on T&P relief valve...

  • Page 10: Recirculation (If Used)

    — Product Manual companion water heater Recirculation (if used) Massachusetts code applications require recirculation Figure 7 Time lag to obtain hot water at fixture for piping or heat-traced piping if the distance from the branch lengths of 10 and 25 feet (ASPE water heater to the furthest fixture exceeds 100 feet.

  • Page 11: Connecting To The Water Heater

    2. See the following pages for piping between boiler and water heater, boiler lower pipe routing and CWH relief valve. a. WM97+70 or 110 boiler: Mixing valve on right side of CWH: page 12 Mixing valve on left side of CWH: page 14 b.

  • Page 12: Boiler/Cwh Piping - 70 Or 110 / Right-Side Mixing Valve

    RIGHT side. The boiler 14. Service tee, 1” (shipped loose with CWH) shown must be either a model WM97+70 or Install the service tee in the location shown in this manual WM97+110. to provide location for the boiler drain valve (item 16). A bushing, 1”x¾”...

  • Page 13: Cwh Circulator Mounting

    Boiler/CWH piping — 70 or 110 / Right-side mixing valve (cont.) Figure 10 Typical piping for WM97+70 or 110 — CWH installed with right- side mixing valve All piping must comply with the instructions in the WM97+ Boiler manual.

  • Page 14: Boiler/Cwh Piping - 70 Or 110 / Left-Side Mixing Valve

    LEFT side. The boiler 14. Service tee, 1” (shipped loose with CWH) shown must be either a model WM97+70 or Install the service tee in the location shown in this manual WM97+110. to provide location for the boiler drain valve (item 16). A bushing, 1”x¾”...

  • Page 15: Cwh Circulator Mounting

    Boiler/CWH piping — 70 or 110 / Left-side mixing valve (cont.) Figure 11 Typical piping for WM97+70 or 110 — CWH installed with left- side mixing valve All piping must comply with the instructions in the WM97+ Boiler manual.

  • Page 16: Boiler/Cwh Piping - 155 / Right-Side Mixing Valve

    The circulator speed MUST be set at “1(LO)” when WM97+ Boiler manual for sizing and installing gas connec- connected to a WM97+70 or 110. The circulator tions. The manual gas valve and piping shown as item 20 must speed MUST be set at “3(HI)” when connected to be installed OUTSIDE the piping access panel and braced/ a WM97+155.

  • Page 17: Cwh Circulator Mounting

    — Product Manual companion water heater Boiler/CWH piping — 155 / Right-side mixing valve (cont.) Figure 12 Typical piping for WM97+155 — CWH installed with right-side mixing valve All piping must comply with the instructions in the WM97+ Boiler manual.

  • Page 18: Boiler/Cwh Piping - 155 / Left-Side Mixing Valve

    The circulator speed MUST be set at “1(LO)” when supported from the wall or other structure. Orient the piping connected to a WM97+70 or 110. The circulator for best routing through one of the piping access panel sides. speed MUST be set at “3(HI)” when connected to 21.

  • Page 19: Cwh Circulator Mounting

    — Product Manual companion water heater Boiler/CWH piping — 155 / Left-side mixing valve (cont.) Figure 13 Typical piping for WM97+155 — CWH installed with left-side mixing valve All piping must comply with the instructions in the WM97+ Boiler manual.

  • Page 20: Wiring

    / or servicing. in this manual. Connect circulator and sensor harnesses Figure 16 WM97+70 or 110 jacket bottom wire 1. All wiring connections to the Companion Water Heater are pre-wired harness openings and available in the WM97+ boiler lower jacket interior.

  • Page 21: Water Heater Filling And Start-Up

    — Product Manual companion water heater Water heater filling and start-up Start-up checklist The installation and water chemistry must meet the requirements below. Failure to comply could result in ❏ ❏ Verify that T&P relief valve is properly installed damage to the water heater, causing possible severe and piped as directed in this manual and per local personal injury, death or substantial property damage.

  • Page 22: Cwh Control Quick Set-Up

    A balance of performance and efficiency. Delivers hot water for a shower, sinks, or faucets continually (except NORMAL WM97+70 model). General setting for most times of the day. Saves energy by operating with lower boiler temperatures and storing tank at lower temperature for lowest standby ECONOMY losses.

  • Page 23: Water Heater Maintenance

    Call qualified service technician to repair leaks or address problems. The CWH must use ONLY the circulator model ❏ ❏ supplied with the unit or suggested by Weil-McLain. The circulator is water-lubricated and does NOT require oiling. ANNUAL maintenance by qualified service technician ❏...

  • Page 24: Wm97+ Control Settings - Advanced

    — Product Manual companion water heater WM97+ Control settings — Advanced Figure 19 WM97+ control menu access — accessing contractor menus — press and hold the UP and DOWN buttons for 7 seconds to go from any screen to the CONTRACTOR MENU screen Part number 635-500-156/0113...

  • Page 25: Dhw Settings

    — Product Manual companion water heater WM97+ Control settings — Advanced (continued) DHW SETTINGS ADJUST SCHEDULES (WEEKDAYS / WEEKENDS) 1. If a CWH is used, the settings for control operation during CWH calls for heat are set under the DHW SETTINGS menus. 1.
  • Page 26 — Product Manual companion water heater WM97+ Control settings — Advanced (continued) Figure 20 DHW SETTINGS Contractor menus (see Figure 21, page 27 for setting values and descriptions) Part number 635-500-156/0113...
  • Page 27 10°F Control shuts down the burner if boiler supply water temperature exceeds: Boiler Target Boiler Diff Off plus Minimum DHW WM97+70 1100 1100 1100 1100 The adjustment limit for these are linked to the Blower Speed — boiler's absolute min as well as High Altitude.
  • Page 28 — Product Manual companion water heater WM97+ Control settings — Advanced (continued) Figure 22 ADVANCED DHW SETTINGS Contractor menus (see Figure 21, page 27 for setting values and descriptions) Part number 635-500-156/0113...

  • Page 29: Troubleshooting

    ❏ ❏ Mixing valve instruction manual CWH Product manual ❏ ❏ ❏ ❏ Get the latest boiler manual and CWH manual revisions from www.Weil-McLain.com. ❏ ❏ Review all manuals before leaving for the jobsite. Tools needed ❏ ❏ Electrical meter to measure voltage and continuity.

  • Page 30: Water Quality

    — Product Manual companion water heater Troubleshooting (continued) Figure 23 Typical problems and causes and page location for details Problem Check possible causes Page Undersized water heater? Check for air in the system. High-flow shower heads? Check tank temperature setting. Insufficient Boiler system improperly sized? Check circulator speed.
  • Page 31 — Product Manual companion water heater Troubleshooting (continued) Insufficient hot water 1 Undersized water heater? • There are many methods of sizing various applications, i.e. ASHRAE sizing tables or ASPE domestic water heating design manual. • Confirm the water demand required for the application. •...
  • Page 32 8 Check DHW circulator speed • The CWH is supplied with a 3-speed circulator. The speed switch on the circulator must be set to: Speed 1 • for WM97+70 or 110 boilers. Speed 3 • for WM97+155 boilers. Part number 635-500-156/0113...
  • Page 33 — Product Manual companion water heater Troubleshooting (continued) Excessive domestic water temperature 1 Adjust WM97+ control settings and check operation. • Follow instructions in the boiler manual and this manual to adjust tank temperature and boiler water temperature. • If controls are set properly, check tank sensor installation and operation. •...
  • Page 34 — Product Manual companion water heater Troubleshooting (continued) Boiler relief valve lifting or weeping 1 Undersized expansion tank? • Insufficient allowance for expansion on the boiler side can cause the boiler pressure relief valve to lift. • The tank must be sized to handle the total volume of water in the boiler system, the boiler and all inter- connecting piping.
  • Page 35 — Product Manual companion water heater Troubleshooting (continued) CWH Temperature/pressure relief valve lifting or weeping 1 Undersized or missing domestic water side expansion tank? • Is there a thermal expansion tank installed on the domestic supply piping and is it properly sized? •...
  • Page 36 • If water is leaking from around one of the tank connections, a weld may have been broken. Contact your Weil-McLain supplier to determine how to handle the problem. Top of tank or enclosure wet 1 Check for leaks from sources other than the water heater •...
  • Page 37 — Product Manual companion water heater Troubleshooting (continued) Water quality problems 1 Water smells like “rotten eggs.” • The most common cause of water to smell like “rotten eggs” is a non-toxic sulfate reducing bacteria. • The bacteria usually enters into the water system through a break in the supply piping or during construction/maintenance of the supply piping.
  • Page 38 — Product Manual companion water heater Troubleshooting (continued) Water quality problems (continued) • This is similar to the reaction that occurs as air bubbles form on the walls of a pan shortly before the water begins to boil. • The release of dissolved gas can also create air pockets and air locks in the water system piping. This can cause spurts of air or gases when opening the hot water faucet.

  • Page 39: Replacement Parts

    — Product Manual companion water heater Replacement parts Figure 24 Water heater replacement parts Description Part Number 100 Tank 635-900-059 110 Jacket front 383-700-211 120 Jacket back 634-200-215 130 Jacket bottom 634-200-216 140 Jacket top 383-700-212 150 Jacket pipe access cover 634-200-218 Jacket retainer magnets (4 563-039-981...

  • Page 40: Determine Required Temperature Rise

    — Product Manual companion water heater Determine required temperature rise Determine domestic Determine required Determine required water inlet water domestic water outlet domestic water temperature — TI temperature — TO temperature rise — TR T1 is the groundwater temperature typical This is the required temperature exiting The required temperature rise is the differ- for the boiler location.

  • Page 41: Ratings

    — Product Manual companion water heater Ratings 70°F CWH Capacity (GPM) @ Temp Rise (For DHW entering temperature of 45°F — capacities will decrease at higher DHW inlet water temperatures) CWH Performance Mode: Boiler Model High Normal Economy (170°F Storage) (150°F Storage) (135°F Storage) Pump Speed...

  • Page 42: Ahri Ratings

    — Product Manual companion water heater ® AHRI ratings AHRI certified ratings 180°F boiler water entering | 58°F to 135°F domestic water Water Minimum Heater Potable Heat Source Standy Minimum Continuous First Hour Heat Output Heat Source First Draw Water Water Heat Heat Source...

  • Page 43: Dimensions

    — Product Manual companion water heater Dimensions Figure 25 Dimensions — CWH Companion Water Heater, right-side mixing valve orientation — All dimensions in INCHES CWH water heater, tank and CWH piping access cover DHW inlet connection (¾” MNPT) enclosure Boiler water RETURN connection DHW outlet connection (¾”...
  • Page 44 — Product Manual companion water heater...

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