Weil-McLain WM97+70 Operating instructions

User’s
Information Manual
Gas-Fired Water Boilers
With or without Companion Water Heater
Available option:
Matching High Performance
Companion Water Heater
(Unit sold separately)
If the information in this manual is not followed exactly, a fire or explosion may result,
causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS —
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any telephone in your building.
• Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation & service must be performed by a qualified installer, service technician or the gas supplier.
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
Please read this page first
To . . .
Read and use . . .
Page
Learn
precautions
See Hazard Definitions, below
3
See illustration at right
2
Prevent air
contamination
Laundry room or pool — make sure
boiler air is piped to boiler per manual.
Read list of air contaminants you must
avoid.
4
Maintain
boiler
Set up a plan for maintaining the
boiler using the schedule included in
this manual.
Schedule an annual start-up by a
qualified service technician before
every heating season.
5
Follow the Lighting instruction sheet
details to start or shutdown your boiler.
9
This page shows display screen
modes and menu access information.
10
WM97+ boiler without CWH — how to
use the USER MENU
12
CWH overview and DANGER
information
13
USER MENU functions and how to set
date/time and maintenance reminder
14
Quick Set-up of CWH Performance
Mode and how to set Scheduled
operation
15
VACATION MODE quick access
16
Locate boiler
components
Start — or —
Shutdown
boiler
Understand
and use the
control
display
WM97+ with
Companion
Water Heater
WM97+ Boiler components
(WM97+70/110 shown)
Piping to system
Pressure/temperature
gauge
Relief valve
ON/OFF Switch
Also available with Companion
Water Heater (not shown). See
page 13 for information.
Control display
and buttons
Hazard definitions
The following defined terms are used throughout this manual to bring
attention to the presence of hazards of various risk levels or to important
information concerning the life of the product.
Indicates presence of hazards that will cause severe personal
injury, death or substantial property damage.
Indicates presence of hazards that can cause severe personal
injury, death or substantial property damage.
Indicates presence of hazards that will or can cause minor
personal injury or property damage.
Indicates special instructions on installation, operation or
maintenance that are important but not related to personal
injury or property damage.
2
Condensate
trap and drain line
(drain line must be
installed by qualified technician, per
boiler manual)
MANUAL GAS VALVE
NOTE: Lower pipes may be
connected to a domestic hot
water storage tank.
Relief valve drain line (must be run to safe
drainage location — must be installed by qualified
technician, per boiler manual)
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
STOP!! — Read before proceeding
Have this boiler serviced/
inspected by a qualified
service technician, at least
annually.
Failure to comply with the above
could result in severe personal
injury, death or substantial property damage.
When calling or writing about the
boiler— Please have the boiler
model number from the boiler
rating label and the CP number
from the boiler jacket.
• Should overheating occur or gas supply fail
to shut off, DO NOT turn off or disconnect electrical
supply to circulator. Instead, shut off the gas supply at
a location external to the appliance.
• Do not use this boiler if any part has been
under water. Immediately call a qualified service
technician to inspect the boiler and to replace any part
of the control system and any gas control that has been
under water.
Failure to adhere to the guidelines on this page can result in severe personal
injury, death or substantial property damage.
Boiler service and maintenance —
Carbon monoxide detector —
• To avoid electric shock, disconnect electrical
supply before performing maintenance.
• A carbon monoxide detector that is wired on the
same electrical circuit as the boiler is strongly recommended.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
• You must maintain the boiler as outlined in the
manual and have the boiler started up and serviced at least annually by a qualified service technician to ensure boiler/system reliability.
Boiler operation —
• Do not block flow of combustion or ventilation air to
boiler. This boiler is equipped with a control which
will automatically shut down the boiler should air or
vent be blocked. If vent or air blockage is easily accessible and removable, remove it. The boiler should
attempt to restart within an hour. If blockage is not
obvious or cannot be removed, have the boiler and
system checked by a qualified service technician.
Boiler water —
• Do not use petroleum-based cleaning or sealing
compounds in boiler system. Gaskets and seals in the
system may be damaged. This can result in substantial
property damage.
• Leaks in boiler or piping must be repaired
at once to prevent make-up water. Use this
boiler ONLY in a closed-loop system. Continual fresh make-up water will reduce boiler life.
Mineral buildup in heat exchangers reduces heat
transfer, overheats the materials, and causes failure.
Addition of oxygen carried in by make-up water can
cause internal corrosion.
• Do not add cold water to hot boiler. Thermal
shock can cause heat exchanger to crack.
Freeze protection fluids —
Combustion air —
• DO NOT obstruct the combustion air intake or
expose the air intake to corrosive chemicals
(see next page).
Part number 550-142-086/0113
• NEVER use automotive or standard glycol antifreeze.
Use only freeze-protection fluids made for hydronic
systems. Follow all guidelines given by the antifreeze
manufacturer. Thoroughly clean and flush any replacement boiler system that has used glycol before
installing the new boiler.
3
WM97+ Gas-fired
water boiler
— User’s Information Manual
Prevent combustion air contamination
Air contamination
Common household and hobby products often contain
fluorine or chlorine compounds. When these chemicals
pass through the boiler, they can form strong acids in
the vent system or boiler. The acid can eat through
the vent or boiler wall, causing serious damage and
presenting a possible threat of flue gas spillage into
the building.
Combustion air contamination:
Ensure that the combustion air will not contain any of
the contaminants in Figure 1.
Combustion air supply openings or intake terminations
must NOT be near a swimming pool, for example.
Avoid areas subject to exhaust fumes from laundry facilities.
These areas will always contain contaminants.
Please read the information on this page.
If the boiler combustion air inlet is
located in any area likely to cause
contamination, or if products which
would contaminate the air cannot be
removed, you must have the combustion air and vent re-piped and
terminated to another location.
Contaminated combustion air will damage the boiler, resulting in possible severe
personal injury, death or substantial
property damage.
Do not operate the WM97+ boiler if
its combustion air inlet is located in
a laundry room or pool facility, for
example. These areas will always contain
hazardous contaminants.
Figure 1 Corrosive contaminants and sources
Products to avoid
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in
household laundry rooms
Adhesives used to fasten building products and other similar products
Excessive dust and dirt
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
4
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
Annual startup and general maintenance
Figure 2 Service and maintenance schedules
OWNER MAINTENANCE
BEGINNING OF SEASON
(see the following pages for instructions)
Contact your boiler service technician to inspect, service and start
up your boiler. You must have an annual start-up performed by
a qualified service technician to ensure reliable operation of the
boiler and system.
• Check boiler area.
DAILY
• Check air openings.
• Check pressure/temperature gauge.
• Verify boiler front door is securely closed.
• Check vent piping.
• Check air piping.
• Check relief valve.
MONTHLY
• Check condensate drain system.
• Check automatic air vents (if used).
• Check display date and time
• CWH installations — see last page of this manual.
EVERY 6 MONTHS
• Check boiler piping (gas and water).
• Operate relief valve.
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.
Part number 550-142-086/0113
5
WM97+ Gas-fired
water boiler
— User’s Information Manual
User maintenance procedures
The boiler should be inspected and started annually, at the beginning of the heating season, only by a qualified service technician. In addition, the maintenance
and care of the boiler designated on page 5 and explained on the following pages
must be performed to assure maximum boiler efficiency and reliability. Failure
to service and maintain the boiler and system could result in equipment failure,
causing possible severe personal injury, death or substantial property damage.
Boiler must
be serviced
and
maintained
The following information provides detailed instructions for completing the
maintenance items listed in the maintenance schedule, page 5. In addition to
this maintenance, the boiler must be serviced and started up at the beginning of
each heating season by a qualified service technician.
DAILY
Check boiler area
To prevent potential of severe personal injury, death or
substantial property damage,
eliminate all materials discussed below from the boiler
vicinity. If contaminants are
found:
Maintenance
1. Verify that combustion and ventilation
air openings to the boiler room and/or
building are open and unobstructed.
2. Verify that boiler vent discharge and air
intake are clean and free of obstructions.
Remove any debris on the air intake or
flue exhaust openings.
Remove products immediately
from the area. If they have been
there for an extended period,
call a qualified service technician to inspect the boiler and
vent system for possible damage from acid corrosion.
Check boiler pressure/
temperature gauge
If products cannot be removed,
immediately call a qualified
service technician to address
the problem.
2. Contact a qualified service technician if
problem persists.
1. Combustible/flammable materials — Do
not store combustible materials, gasoline
or any other flammable vapors or liquids
near the boiler. Remove immediately if
found.
2. Air contaminants — Products containing
chlorine or fluorine, if allowed to contaminate the boiler intake air, will cause
acidic condensate in the vent and boiler.
This will cause significant damage to the
vent and/or boiler if allowed to continue.
3. Read the list of potential materials listed
on page 4 of this manual. If any of these
products are in the room from which
the boiler takes its combustion air, they
must be removed immediately or the
boiler combustion air must be supplied
from outside.
4. See WARNING above.
6
Check air openings
1. Make sure the pressure reading on the
boiler pressure/temperature gauge does
not exceed 24 psig. Higher pressure may
indicate a problem with the expansion
tank.
Verify that boiler door is
securely closed
1. Visually inspect boiler front door to be
sure it is sealed all around its perimeter.
Verify that the two door latches are tight.
The boiler front door must be
securely fastened to the boiler
to prevent boiler from drawing
air from inside the boiler room.
This is particularly important if
the boiler is located in the same
room as other appliances.
Failure to keep the door securely fastened could result in
severe personal injury or death.
Contact your installer or technician immediately if the front
door does not close correctly
or if the door gaskets are damaged.
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
User maintenance procedures
MONTHLY
Maintenance
(continued)
Check vent & air piping
1. Visually inspect the flue gas vent piping
and air piping for any signs of blockage,
leakage or deterioration of the piping.
Notify your qualified service technician
at once if you find any problem.
Failure to inspect the vent/air
system as noted above and have
them repaired by a qualified
service technician can result
in vent system failure, causing
severe personal injury or death.
5. Have vent replaced if it does not operate
correctly.
Figure 3 Boiler condensate trap
Check the relief valve
1. Inspect the boiler relief valve and the
relief valve discharge pipe for signs of
weeping or leakage.
2. If the relief valve often weeps, the expansion tank may not be working properly.
Immediately contact your qualified service technician to inspect the boiler and
system.
Check the condensate
drain system
1. Visually inspect the condensate drain
tubing and the end of the tube. Make
sure the tube is in good condition and
that condensate can run freely.
2. Inspect the boiler condensate trap, located under the boiler (see Figure 3). Make
sure the ball float in the trap is in place
and appears to be free to move. Make sure
the trap has water in it.
3. Contact a boiler service technician if you
observe any problems.
Ball float
Contact a boiler service technician immediately if you find
the trap dry (no water inside).
Figure 4 Automatic air vent
A
B
Check automatic air vents
(if used — automatic air vents
must be used with diaghragm-type
expansion tanks only)
1. See Figure 4.
2. Remove the cap from any automatic air
vent in the system and check operation
by depressing valve “B” slightly with the
tip of a screwdriver.
Scald hazard — Water from
air vent may be very hot. Avoid
contact to prevent possible
severe personal injury.
3. If the air vent valve appears to be working freely and not leaking, replace cap “A”,
twisting all the way on.
4. Loosen cap “A” one turn to allow vent to
operate.
Part number 550-142-086/0113
85036
Check display date and
time
1. Observe the date and time shown in the
upper right of the control display.
2. If the date or time is incorrect, follow the
instructions in Figure 6, page 10 and Figure 9, page 12 to access the USER MENU
and change the date and/or time settings.
3. Keeping the data and time current makes
sure the control can record problems
accurately.
7
WM97+ Gas-fired
water boiler
— User’s Information Manual
User maintenance procedures
EVERY
6 MONTHS
Maintenance
(continued)
Check boiler piping
1. Check all gas lines and smell for gas
odors. Perform gas leak inspection per
steps 1 through 7, Operating Instructions,
page 9. If gas odor or leak is detected,
immediately shut down boiler following
procedures on page 9. Call a qualified
service technician.
2. Visually inspect for water leaks around
all piping, circulators, relief valves and
other fittings.
3. Immediately call a qualified service technician to repair any leaks.
Have leaks fixed at once by a
qualified service technician.
Continual fresh makeup water
will reduce boiler life. Minerals
can build up in the heat exchanger, reducing heat transfer
and causing overheating. Heat
exchanger failure can occur.
Do not use p e t ro l e u m -
based cleaning or sealing
compounds in boiler system.
Severe damage to boiler and
system components can occur,
resulting in possible severe
personal injury, death or substantial property damage.
Operate boiler relief valve
1. Before proceeding, verify that the relief
valve outlet has been piped to a safe place
of discharge, avoiding any possibility of
scalding from hot water.
3. Lift the relief valve top lever slightly, allowing water to relieve through the valve
and discharge piping.
4. If water flows freely, release the lever and
allow the valve to seat. Watch the end of
the relief valve discharge pipe to ensure
that the valve does not weep after the line
has had time to drain. If the valve weeps,
lift the seat again to attempt to clean the
valve seat. If the valve continues to weep
afterwards, contact your qualified service
technician to inspect the valve and system.
5. If water does not flow from the valve
when you lift the lever completely, the
valve or discharge line may be blocked.
Immediately shutdown the boiler, following the lighting instructions on the
inside jacket top. Call your qualified
service technician to inspect the boiler
and system.
To avoid water damage or scalding due to valve operation, a
metal discharge line must be
connected to relief valve outlet and run to a safe place of
disposal. This discharge line
must be installed by a qualifed
heating installer or service
technician in accordance with
the instructions in the WM97+
Boiler Manual. The discharge
line must be terminated so
as to eliminate possibility of
severe burns should the valve
discharge.
2. Read the boiler pressure/temperature
gauge to make sure the system is pressurized.
8
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
OPERATING INSTRUCTIONS
Figure 5 Operating instructions (see page 2 for location of manual gas valve)
Part number 550-142-086/0113
9
WM97+ Gas-fired
water boiler
— User’s Information Manual
The WM97+ control display
Figure 6 WM97+ boiler control display states — press the RIGHT ARROW button to see the INFORMATION screen
10
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
The WM97+ control display
(continued)
Figure 7 WM97+ boiler control MAINTENANCE notice screens (alternates between wrench screen and maintenance screen)
Figure 8 WM97+ boiler control display LOCKOUT SCREEN — screen turns red when boiler locks out —
highlight and select MANUAL RESET to reset boiler as shown below.
Part number 550-142-086/0113
11
WM97+ Gas-fired
water boiler
— User’s Information Manual
The WM97+ control settings (without CWH)
USER Menu
functions
Date and time
Maintenance information
1. Set year, month, date, hour and minute
on the five screens shown below.
2. Keep date and time current to ensure that
maintenance information and control
fault history will be accurate.
1. Obtain installer information, installation
date and maintenance schedule (last and
next dates).
2. Use the final screen to reset the maintenance reminder.
Figure 9 USER Menu access and navigation (for WM97+ boiler without optional Companion Water Heater) — Access USER
MENU by selecting SETTINGS on the STATUS screen (see Figure 6, page 10)
12
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
WM97+ Boiler with Companion Water Heater
(CWH)
See the next three pages for information on control settings and adjustments for boilers with CWH units.
WM97+
Boiler
Hot Water Can Scald!
•
•
•
Optional
WM97+
Companion
Water Heater
Part number 550-142-086/0113
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald
and cause permanent injury.
Children, elderly, and infirm or physically handicapped persons are more likely to be permanently
injured by hot water. Never leave them unattended
in bathtub or shower. Never allow small children to
use a hot water tap or draw their own bath.
• If anyone using hot water in the building fits
the above description, or if state laws or local
codes require certain water temperatures at hot
water taps, you must take special precautions:
• Use lowest possible temperature setting.
• Install a thermostatic protective device at
each point of use in addition to the mixing
valve installed at the water heater.
Water passing out of drain valves may be extremely
hot. To avoid injury:
• Make sure all connections are tight.
• Direct water flow away from any person.
For all applications:
Protection must be taken against excessive
temperature and pressure! — Install a temperature & pressure (T&P) relief valve (like
that provided with the water heater) and thermostatic mixing valve (like that provided with
the water heater). In addition, a thermostatic
protective device at each point of use may
also be necessary.
13
WM97+ Gas-fired
USER Menu
functions
water boiler
— User’s Information Manual
CWH Date, Time & Maintenance
Date and time
1. Set year, month, date, hour
and minute on the five
screens shown at right.
2. Keep date and time current to ensure that maintenance information, control
fault history and schedule
settings (if SCHEDULE
mode is used) will be accurate.
Maintenance
information
1. Obtain installer information, installation date and
maintenance schedule (last
and next dates).
2. Use the final screen to
reset the maintenance
reminder.
DHW Settings
1. See page 15 for explanation of performance mode
settings.
2. Use the TANK STORAGE
TEMPERATURE setting to
customize the tank storage
temperature. This should
not be necessary in most
cases. Tank temperature
is automatically set when
selecting a performance
mode.
Hot water
can scald.
See DANGER information
on page 13 before adjusting.
14
Part number 550-142-086/0113
WM97+ Gas-fired
water boiler
— User’s Information Manual
CWH Performance Mode quick set-up
Hot water can scald. Read DANGER information on page 13 before adjusting.
Mode
Description
If selected by a User — CWH operation is turned off; can be turned
on by user in the Performance Mode Menu
OFF-DISABLED NOTICE — If a Contractor selects OFF-DISABLE, the CWH cannot be
turned on by the user. It can only be activated by a Contractor.
Delivers the highest performance available and maximizes the energy
HIGH
of the stored water for demanding applications. Use during peakPERFORMANCE demand periods when multiple fixtures will be running.
NORMAL
A balance of performance and efficiency. Delivers hot water for a
shower, sinks, or faucets continually (except WM97+70 model).
General setting for most times of the day.
ECONOMY
Saves energy by operating with lower boiler temperatures and
storing tank at lower temperature for lowest standby losses. Not
recommended for showering with 70°F temperature rise (except for
the WM97+155 model). Ideal setting in schedule mode for low-use
periods.
VACATION
Maintains tank temperature above 50°F to deter freezing in tank. This
mode will not supply hot water to the user.
SCHEDULED
This mode allows programming up to 4 different performance modes
to occur at different times of the day. There are different schedules
for Weekdays (M-F) and Weekends. This allows energy savings by
keeping the tank at low temperatures when not needed and meeting
peak demands during times of typical high usage. These times must
be programmed by the contractor or user.
Part number 550-142-086/0113
15
WM97+ Gas-fired
water boiler
— User’s Information Manual
Vacation mode quick access
Vacation mode access
1. Use the sequence shown below for quick access to enable VACATION mode.
2. When VACATION mode is turned OFF, the WM97+ control reverts to the Performance Mode previously selected.
ATTENTION CWH USER!
Have the water heater serviced at least once annually by a qualified
service technician.
Follow the maintenance procedures below at least monthly.
Failure to comply with the above can result in severe personal injury, death
or substantial property damage.
MONTHLY maintenance by user
• At least MONTHLY, visually check valves, pipes and fittings for leaks.
• Check hot water supply at several outlets. Make sure water temperature is not too hot.
• Call qualified service technician to repair leaks or address problems.
16