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. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage. Part number 550-142-120/0113 WM97+ GAS-FIRED WATER BOILER — Boiler Manual 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. Heat exchanger access cover/burner mounting plate two space-heating or three space heating). DHW direct-connected 3. Blower to the bottom piping connections can be set for domestic priority. The advanced blower design and air inlet silencer on WM97+ boilers 17. Multi-position WM97+ control housing result in very quiet operation. The WM97+ control is mounted in a plastic housing assembly that Air enters the boiler enclosure through the air intake adapter (18), can rotate forward for rear access to the control boards or for access flows through the enclosure, enters the air inlet silencer (5), then to boiler components. It can also be removed through slots in the enters the blower. The blower pulls air through the silencer and boiler jacket sides. pushes it into the venturi (6), where it mixes with gas before enter- ing the burner. 18. Air intake adapter (fits 3” PVC) 4. Gas valve 19. Electrical entrances The automatic gas valve (4) senses the vacuum in the venturi caused The left side electrical enclosure (19a) houses the line voltage ter- by flowing air, and allows gas to flow when power is applied. A minal block. The right side electrical enclosure (19b) houses low manual gas valve is shipped loose with the boiler. It allows shutting voltage terminals. off the gas supply for servicing or shutdown. See instructions in this manual for manual gas valve installation. 20. Boiler drain valve (not shown) Shipped loose for field piping to DHW return line at bottom of 5. Air inlet silencer boiler jacket. See instructions in this manual. The horn-shaped air inlet silencer significantly reduces fan noise, providing exceptionally quiet operation. 21. Integral expansion tank The 3.2-gallon internal expansion tank is factory installed as shown. 6. Venturi It is supplied with an isolation valve that allows removal for service When air flows through the venturi, it creates a negative pressure. or replacement without draining the system or boiler. This vacuum pulls gas from the gas valve. So gas will only flow if air is flowing. The gas mixes with air in the venturi. The gas/air 22. Flue gas condensate drain mixture then flows into the burner. Flexible plastic hose is provided to adapt to 1” PVC (fits in 1” PVC coupling). 7. Outlet water temperature dual sensor This dual sensor monitors boiler outlet water temperature. The 23. Flue gas condensate drain trap assembly WM97+ control adjusts boiler firing rate so the outlet water tem- The condensate trap assembly is field-installed, connected to the perature is correct, based on the calculated (if outdoor reset used condensate trap nozzle as shown in this manual. — see page 133) or fixed target temperature. 24. Front door 8. Return water temperature sensor The front door is sealed to the boiler assembly around its entire This sensor monitors return water temperature. The WM97+ perimeter. control reduces or increases boiler input, depending on how close the return water temperature is to the outlet water temperature. 25. Front door latches Two latches secure the door in place. 9. DHW tank or CWH piping connections An indirect storage water heater can be piped to these connections 26. Ignition electrode/flame sensor for direct connection to the boiler. The installer must supply the The burner flame is ignited by applying a high voltage to the igni- circulator for a DHW boiler water loop. CWH (Companion Water tion electrode. This causes a spark (from electrode to ground). After Heater) units are shipped with a circulator. ignition, the electrode measures flame signal. 10. Electronic display & buttons 27. Flame inspection window The electronic display is used to configure boiler settings and moni- The quartz glass window provides a view of the burner surface, the tor boiler operation. flame, and the ignition electrode. The buttons allow changing display mode, selecting and adjusting control settings, and resetting the control after lockout. 28. Flue gas dual sensor This dual sensor monitors the flue gas exit temperature. The 11. Flue adapter (fits 3” PVC) WM97+ control will shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe and the heat exchanger 12. Burner from overheating. Made with high-grade stainless steel construction, the burner uses pre-mixed air and gas. The burner and control provide modulat- 29. ON/OFF switch ing firing. 30. Primary/secondary shut-off valve 13. Water outlet pipe (system supply) Supply and return from the heating system are connected to the pipes out the top of the boiler. When p/s shut-off valve is open, the 14. Water return pipe (system return) piping connection is primary/secondary, requiring a separate circu- 15. Gas connection pipe lator for the system. When the valve is closed, the boiler circulator Manual gas valve is shipped loose. Other ½” NPT gas connection is used for boiler and system flow. pipe and fittings (including union) shown must be supplied by 31. Low water cut-off the installer. 32. Boiler circulator 16. WM97+ control The WM97+ control responds to signals from the room thermostats, 33. Gas valve reference hose DHW aquastats (if used), boiler sensors (boiler return, boiler supply, This rubber line connects the gas valve diaphragm reference flue temperature, and outdoor temperature, if used — see page 133). chamber to the venturi intake to insure the valve senses the correct The control automatically adjusts blower speed (and gas flow rate) reference pressure. – 2 – Part number 550-142-120/0113 WM97+ GAS-FIRED WATER BOILER — Boiler Manual The WM97+70 & 110 Gas-fired water boiler (cont.) Part number 550-142-120/0113 – 3 – WM97+ GAS-FIRED WATER BOILER — Boiler Manual 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 3. Blower domestic priority. The advanced blower design and air inlet silencer on WM97+ boilers result in very quiet operation. 17. Multi-position WM97+ control housing Air enters the boiler enclosure through the air intake adapter (18), The WM97+ control is mounted in a plastic housing assembly that flows through the enclosure, enters the air inlet silencer (5), then can rotate forward for rear access to the control boards or for access enters the blower. The blower pulls air through the silencer and to boiler components. It can also be removed through slots in the the venturi (6), where it mixes with gas before entering the blower. boiler jacket sides. 4. Gas valve 18. Air intake adapter (fits 3” PVC) The automatic gas valve (4) senses the vacuum in the venturi caused by flowing air, and allows gas to flow when power is applied. A 19. Electrical entrances manual gas valve is shipped loose with the boiler. It allows shutting off the gas supply for servicing or shutdown. See instructions in this The left side electrical enclosure (19a) houses the line voltage ter- manual for manual gas valve installation. minal block. The right side electrical enclosure (19b) houses low voltage terminals. 5. Air inlet silencer The horn-shaped air inlet silencer significantly reduces fan noise, 20. Boiler drain valve (not shown) providing exceptionally quiet operation. Shipped loose for field piping to DHW return line at bottom of 6. Venturi boiler jacket. See instructions in this manual. When air flows through the venturi, it creates a negative pressure. This vacuum pulls gas from the gas valve. So gas will only flow if 21. Boiler circulator air is flowing. The gas mixes with air in the venturi. The gas/air mixture then flows into the burner. 22. Flue gas condensate drain Flexible plastic hose is provided to adapt to 1” PVC (fits in 1” PVC 7. Outlet water temperature dual sensor coupling). This dual sensor monitors boiler outlet water temperature. The WM97+ control adjusts boiler firing rate so the outlet water tem- perature is correct, based on the calculated (if outdoor reset used 23. Flue gas condensate drain trap assembly — see page 133) or fixed target temperature. The condensate trap assembly is field-installed, connected to the condensate trap nozzle as shown in this manual. 8. Return water temperature sensor This sensor monitors return water temperature. The WM97+ 24. Front door control reduces or increases boiler input, depending on how close the return water temperature is to the outlet water temperature. The front door is sealed to the boiler assembly around its entire perimeter. 9. DHW tank or CWH piping connections An indirect storage water heater can be piped to these connections 25. Front door latches for direct connection to the boiler. The installer must supply the Two latches secure the door in place. circulator for a DHW boiler water loop. CWH (Companion Water Heater) units are shipped with a circulator. 26.