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Weil-McLain SVF 725 Manual

Weil-McLain SVF 725 Manual

Commercial condensing gas-fired water boilers
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Models 725 / 850
Commercial Condensing
Gas-Fired Water Boilers
Boiler Manual
WARNING
!
Installation and service of the boiler must be performed by a qualified installer or service technician.
Read all instructions, including this manual and all other information shipped with the boiler, before
installation or operation. Perform steps in the order given. Failure to comply can result in severe
personal injury, death or substantial property damage.
Manual Part Number 550-100-290/0124

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Summary of Contents for Weil-McLain SVF 725

  • Page 1 Models 725 / 850 Commercial Condensing Gas-Fired Water Boilers Boiler Manual WARNING Installation and service of the boiler must be performed by a qualified installer or service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installation or operation.
  • Page 2 Table of ConTenTs series boiler manual 725/850 Contents Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Vent and Air Adapters Abbreviations .
  • Page 3 series boiler manual Table of ConTenTs 725/850 Field Wiring . . . . . . . . . . . . . . . . . . . . . . 61 Gas Valve Leakage Testing Schematic Diagram Verification Check List...
  • Page 4 Table of ConTenTs series boiler manual 725/850 Contents, continued SECTION 7 – PARTS SECTION 8 – SERVICE INFORMATION Miscellaneous Parts . . . . . . . . . . . . . . . . . . 111 Ratings .
  • Page 5 series boiler manual safeTy 725/850 SeCTion 1 Safety Please Read Before Proceeding This section is intended to provide safety information for installers and users WARNING Section Contents Adhere to all following guidelines and instructions in this section. Failure to adhere to Safety Signals these guidelines can result in severe personal Please Read Before Proceeding...
  • Page 6 safeTy series boiler manual 725/850 Please Read Before Proceeding, continued Servicing a Boiler Commonwealth of Massachusetts • To avoid electric shock, disconnect all electrical When the boiler is installed within the Commonwealth supplies to the boiler before performing maintenance of Massachusetts: •...
  • Page 7 series boiler manual safeTy 725/850 Frozen Water Damage Power outages, unattended residences or buildings, boiler component failures, or other electrical system failures in cold weather can result in frozen plumbing and water damage in a matter of hours Consult with a boiler contractor or a home security agent to take preventative actions, such as installing a security system that operates during power outages, senses...
  • Page 8 safeTy series boiler manual 725/850 This page intentionally left blank 550-100-290/0124...

  • Page 9: Table Of Contents

    series boiler manual insTallaTion 725/850 SeCTion 2 Installation This section is intended to provide installation • Where required by the authority having instructions for qualified heating installers. jurisdiction, the installation must conform to the Standard for Controls and Safety Devices for Section Contents Automatically Fired Boilers –...
  • Page 10 Minimum foundation dimensions The SVF Boiler is approved for installation on Boiler Model Minimum Dimensions (inches) combustible flooring, but must never be installed on SVF 725 29 x 44 x 2 carpeting SVF 850 29 x 44 x 2 WARNING...
  • Page 11 series boiler manual insTallaTion 725/850 Clearances IMPORTANT Hot water pipes, vent pipes, and piping ends all have a minimum clearance requirement from combustible Without the recommended minimum clearances for surfaces There are also minimum allowable service service access, it may not be possible to service the clearances and recommended service access boiler without removing it from the space.
  • Page 12 insTallaTion series boiler manual 725/850 Prepare Boiler Location, continued Air Openings - General SVF Boiler in a Room With Other Appliances: Follow the National Fuel Gas Code – ANSI Z223 1/ Direct Vent installations: Size openings only on NFPA 54, latest edition, for the U S Follow the the basis of the other appliances in the space No Natural Gas and Propane Installation Code –...
  • Page 13 series boiler manual insTallaTion 725/850 Preparing for Multiple Boilers Provide the clearances shown in Figure 2 and Chalk-line boiler locations on foundation or boiler follow local codes Other layouts can be used if room floor. all required clearances are maintained Remove boilers from the crate and assemble Construct boiler foundation if the floor in the boiler according to instructions in this manual...

  • Page 14: Prepare The Boiler

    insTallaTion series boiler manual 725/850 Prepare the Boiler Removing the Boiler from the Crate WARNING Leave the boiler in the crate pallet until ready to place The boiler is heavy. Use caution not to drop in the final location. Follow all uncrating instructions. the boiler.
  • Page 15 series boiler manual insTallaTion 725/850 Placing the Boiler Figure 4 Leveling legs warning Roll the boiler down the ramp and move the boiler into position The boiler must be unloaded from WARNING the pallet onto a solid, level surface WARNING LEVELING LEGS The boiler is heavy.
  • Page 16 There is one orifice for it to the blower Ensure that the gas hookup the SVF 725/850 boiler. The orifice size is 0.559". is in the down orientation, and the O-ring is Verify the orifice sizes on the mixer. The top seated properly between the blower and mixer orifice is 7.4 mm and the bottom orifice is 9.4 mm.
  • Page 17 series boiler manual insTallaTion 725/850 Propane Conversion Procedure, continued Figure 7 Hydrostatic test piping connections - flanges, *PROPANE (LP) DESIGN AVAILABILITY PENDING* valves, and gaskets provided by installer 12 Install the propane orifice between the gas pipe and the bottom of the mixer, wedged between the Relief Valve Relief Valve two square gaskets supplied with the propane...
  • Page 18 insTallaTion series boiler manual 725/850 Prepare the Boiler, continued Pressure Test Precautions WARNING DO NOT leave the boiler unattended at any Failure to comply with these precautions can time during testing. A cold water fill could result in severe personal injury, death, or expand and cause excessive pressure, substantial property damage.

  • Page 19: Install Water Piping

    series boiler manual insTallaTion 725/850 Install Water Piping General Piping Information Low water cutoff: A push-to-test low water cutoff is factory installed on NOTICE the switch panel on the left side of the control tray The low water cutoff probe is mounted on the front of Use two wrenches when tightening water piping the heat exchanger at the boiler with one at the boiler interior piping to...
  • Page 20 insTallaTion series boiler manual 725/850 Install Water Piping, continued Relief Valve Installation Figure 8 Relief Valve Installed WARNING Do NOT install a relief valve with a pressure Relief Valve, higher than 160 psig. This is the maximum installed allowable relief valve setting for the SVF boiler. The boiler is shipped with a 30 psig relief valve.
  • Page 21 * Suggested design flow rate (30°F temp, rise, water only) • Use Primary/Secondary piping **SVF 725 minimum flow rates (GPM): High Fire = 23, Low Fire = 4 ***SVF 850 minimum flow rates (GPM): High Fire = 27, Low Fire = 4 •...
  • Page 22 insTallaTion series boiler manual 725/850 Install Water Piping, continued Expansion Tank and Make-up Water Figure 10 Expansion tank piping - diaphragm-type tank Ensure the expansion tank size will handle boiler and system water volume and temperature See Table 19, From boiler/system To system page 121 for boiler water content The expansion tank must be located as shown in...
  • Page 23 series boiler manual insTallaTion 725/850 ZONE VALVE Zoning - General The information on this page applies to all zone valve Controlling the pumps: zoning applications The control can control the boiler pump and up to three other pumps Activation of the external pumps NOTICE must be achieved by closing a relay Relay A is generally set to the boiler pump...
  • Page 24 insTallaTion series boiler manual 725/850 Install Water Piping, continued Figure 12 Zone valve zoning with optional DHW piping ZONE VALVE Zoning - Primary/Secondary Additional Zones IMPORTANT ZONE 1 Refer to page 23 for general zone valve zoning information for all applications before installation. Do not exceed 8 pipe diameters apart...
  • Page 25 series boiler manual insTallaTion 725/850 ZONE VALVE Zoning - Variable Primary Flow Figure 14 Variable primary flow, DHW as zone IMPORTANT Refer to page 23 for general zone valve zoning Additional information for all applications before installation. Zones ZONE 1 This configuration is for applications that use a variable flow system pump.
  • Page 26 insTallaTion series boiler manual 725/850 Install Water Piping, continued Figure 16 Pump zoning with optional DHW piping ZONE VALVE Zoning - Circulator Zoning, Additional Zones Primary/Secondary ZONE 1 IMPORTANT Do not exceed Refer to page 23 for general zone valve zoning 8 pipe diameters apart information for all applications before installation.
  • Page 27 series boiler manual insTallaTion 725/850 ZONE VALVE Zoning - Water Chiller Figure 18 Chilled water system with optional DHW piping Systems, Primary/Secondary Additional Zones IMPORTANT ZONE 1 Refer to page 23 for general zone valve zoning information for all applications before installation. Do not exceed 8 pipe diameters This configuration is for applications using a chilled...

  • Page 28: Commonwealth Of Massachusetts Installations

    insTallaTion series boiler manual 725/850 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. For all sidewall horizontally-vented The following equipment is exempt from REQUIREMENTS:...

  • Page 29: Venting And Combustion Air - General

    series boiler manual insTallaTion 725/850 Venting and Combustion Air - General Code Compliance Combustion air must be supplied through openings into the boiler room Follow the instructions in Venting and combustion air piping installations this manual and comply with all applicable codes must provide provisions in accordance with “Air for Combustion air must not be exposed to any of the Combustion and Ventilation,”...
  • Page 30 insTallaTion series boiler manual 725/850 Venting and Combustion Air - General, continued Using a Chimney Table 7 Corrosive contaminants and sources WARNING Products to avoid A chimney must only be used as a chase for vent Spray cans containing chloro/fluorocarbons and air piping and must meet all requirements Permanent wave solutions as listed below.
  • Page 31 series boiler manual insTallaTion 725/850 Vent and Air Adapters Take the 2nd clamp and feed it through the other end of the assembly straps Adjust this clamp so it Vent connections are sized for DuraVent is roughly 7-9 inches in diameter to match the first Fas-N-Seal , DuraVent PolyPro , PVC, and...
  • Page 32 insTallaTion series boiler manual 725/850 Venting and Combustion Air - General, continued The flue support clamp must be installed to help Table 8 Vent and air adapter part numbers secure the exhaust pipe to the boiler The clamp is provided with the boiler Reference Figure 21 for SVF Boiler Models 725/850 installation Mechanical...

  • Page 33: Venting And Combustion Air Options

    series boiler manual insTallaTion 725/850 Venting and Combustion Air Options Existing Vent System DANGER Turn on the clothes dryer and any other appliance DO NOT install the SVF boiler into a common not connected to the common venting system Turn vent with any other appliance.
  • Page 34 insTallaTion series boiler manual 725/850 Venting and Combustion Air Options, continued WARNING Vent and Air Piping Materials Use only the materials listed in Table 9 for vent and air Failure to supply locking collars and seal the piping Ensure that all materials used meet local codes joints could cause vent and air piping leakage, See Table 8, page 32 for adapter part numbers which can result in severe personal injury, death,...
  • Page 35 Scfm Inches W C flue temperature of 200°F, and it will shut down 725,000 -0 001 to -0 100 6" SVF 725 once it exceeds 210°F. The flue gas temperature 850,000 -0 001 to -0 100 6" SVF 850 standard is within 20°F and 30°F of the return water *The SVF boiler vent or air connection is sized for 6"...
  • Page 36 insTallaTion series boiler manual 725/850 Venting and Combustion Air Options, continued Code Compliance: Category II Requirements, continued Venting and combustion air piping installations must provide provisions for combustion and ventilation air in accordance with the section, “Venting of WARNING Equipment" of the National Fuel Gas Code – ANSI Install a Category II boiler system per all Z223 1/NFPA 54, latest edition, section "Venting Systems and Air Supply for Appliances"...
  • Page 37 series boiler manual insTallaTion 725/850 Vent and Air Terminations for Category IV The figure below lists the acceptable vent and air pipe terminations for Category IV as described in this manual. The SVF boiler vent or air connection is sized for 6" DuraVent Fas-N-Seal, DuraVent PolyPro, PVC, and CPVC The installer must provide the correct adapters/reducers needed to connect to other approved vent manufacturer’s products The air inlet adapter is installed on the back of the boiler as shown in Figure 73, page 113...

  • Page 38: Direct Exhaust - Room Air Openings (Cat Ii And Iv)

    insTallaTion series boiler manual 725/850 DIRECT EXHAUST - Room Air Openings (Cat. II and IV) Combustion Air Provision Free area and louvers The free area of openings means the area after NOTICE reduction for any installed louvers or grilles Be sure to consider this reduction when sizing the air opening A bird screen must be added to the inlet adapter to prevent large debris from entering the boiler cabinet.
  • Page 39 series boiler manual insTallaTion 725/850 Figure 25 Minimum combustion air openings for direct exhaust applications Air openings SVF boiler WITH other appliances in SVF boiler WITHOUT other The required air opening sizes below are FREE the same room appliances in the same room AREA, after reduction for louver obstruction See the important below for large spaces 0 to 12"...

  • Page 40: Direct Exhaust - Vertical Termination (Cat Ii And Iv)

    insTallaTion series boiler manual 725/850 DIRECT EXHAUST - Vertical Termination (Cat. II and IV) Vertical Termination Location Figure 26 Vertical direct exhaust termination The vent termination must be installed as shown in Figure 26 The termination placement must comply B i r d B i r d with clearances and limitations shown in Figure 27, s c r e e...
  • Page 41 series boiler manual insTallaTion 725/850 Vent Piping Installation Vent Termination Installation WARNING Vent pipe penetration: Use only the vent materials and kits listed in a Cut a hole for the vent pipe Table 9, page 34. Failure to comply can result b For combustible construction, size the vent in severe personal injury, death, or substantial pipe hole at least 3/8"...

  • Page 42: Direct Exhaust - Sidewall Termination (Category Iv)

    insTallaTion series boiler manual 725/850 DIRECT EXHAUST - Sidewall Termination (Category IV) Sidewall Termination Location WARNING • Vent and air terminations must be installed at least Follow all location requirements in this section. 12" (0 31m) above grade and snow line Failure to comply can result in severe personal •...
  • Page 43 series boiler manual insTallaTion 725/850 Determine Termination Location Figure 28 Sidewall direct exhaust termination The vent termination must be installed as shown in Figure 28 and Figure 30, page 44 The termination B i r d B i r d s c r e e s c r e e placement must comply with clearances and...
  • Page 44 insTallaTion series boiler manual 725/850 DIRECT EXHAUST - Sidewall Termination, continued (Category IV) Figure 29 Multiple boiler direct exhaust sidewall Vent Termination Installation terminations Maintain the required dimensions of the finished termination piping as shown in Figure 27, page 42 B i r d B i r d V e n t...

  • Page 45: Direct Vent - Room Air Openings (Category Iv)

    series boiler manual insTallaTion 725/850 DIRECT VENT - Room Air Openings (Category IV) Combustion and Ventilation Air Provision Special Considerations For direct vent installations, combustion air must be Tight construction ducted directly from outside to the boiler air intake fitting. Sidewall or vertical options are available. The ANSI Z223.1/NFPA 54 defines unusually tight boiler room will still require air openings for ventilation construction where all of the following is true:...
  • Page 46 insTallaTion series boiler manual 725/850 DIRECT VENT - Room Air Openings, continued (Category IV) Figure 31 Minimum combustion air openings for direct vent applications Air openings SVF boiler WITH other appliances in the SVF boiler WITHOUT other appliances The required air opening sizes below are FREE AREA, after reduction for louver obstruction same room in the same room...
  • Page 47 series boiler manual insTallaTion 725/850 Combustion Air Manifold Option Figure 32 Manifolded combustion air option Multiple SVF boilers can use a common combustion air manifold Size the duct to provide at least one square inch per 2,000 Btuh total input of connected Minimum 3 feet below any vent termination within 10 feet boilers Provide a minimum clearance to adjacent Air duct...

  • Page 48: Direct Vent - Vertical Termination (Category Iv)

    insTallaTion series boiler manual 725/850 DIRECT VENT - Vertical Termination (Category IV) Vertical Termination Location Figure 33 Vertical direct vent terminations The vent and air terminations must be installed V E N T V E N T as shown in Figure 33 The air termination can be through either the roof or a sidewall as shown The A I R A I R...
  • Page 49 series boiler manual insTallaTion 725/850 Vent and Air Termination Installation Figure 34 Vertical vent & air terminations Maintain the required dimensions of the finished termination piping as shown in the figures in this B I R D B I R D section S C R E S C R E...
  • Page 50 insTallaTion series boiler manual 725/850 DIRECT VENT - Vertical Termination, continued (Category IV) Vertical vent termination with sidewall air Figure 36 Vertical vent with sidewall air - sidewall air termination as shown in Figure 37: termination assembly a Provide and install corrosion-resistant metal stop plates See Figure 36, item 3 b The hole size in the stop plates must be just larger than the vent pipe diameter...
  • Page 51 series boiler manual insTallaTion 725/850 Sidewall Termination Location WARNING • Vent and air terminations must be installed at Follow all location requirements in this section. least 12" (0 31m) above grade and snow line Failure to comply can result in severe personal •...

  • Page 52: Direct Vent - Sidewall Termination (Category Iv)

    insTallaTion series boiler manual 725/850 DIRECT VENT - Sidewall Termination (Category IV) Figure 39 Sidewall direct vent terminations Determine Termination Location Air elbow snorkel option The vent termination must be installed as shown in Figure 39 and Figure 41, page 54 The termination o r e o r e s n o m...
  • Page 53 series boiler manual insTallaTion 725/850 Slope vent piping toward the boiler a minimum of External venting greater than 4 ft requires an 1/4" per foot in horizontal runs or larger per vent insulated enclosure around the vent and air pipes pipe manufacturer’s instructions The vent and air terminations must exit through Support piping independently of the boiler Install...
  • Page 54 insTallaTion series boiler manual 725/850 DIRECT VENT - Sidewall Termination, continued (Category IV) Figure 41 Sidewall termination assembly for direct vent installations 220088 Insert vent piping from the Vent termination elbow - outside until the female end outward-facing 90-degree shoulder rests against the Air termination elbow - outside stop plate down-turned 90-degree...

  • Page 55: Install Condensate Components

    Provide an external power source for the pump Minimum recommended condensate pump capacity in gallons per hour per boiler: • SVF 725, 15 GPH • SVF 850, 25 GPH When sizing condensate pumps, make sure to include the total load of all SVF boilers connected...

  • Page 56: Gas Piping

    insTallaTion series boiler manual 725/850 Gas Piping Gas Supply Piping Connection Figure 44 Gas supply piping connection (fittings and gas valve supplied by installer) WARNING Use two wrenches when tightening gas piping at the boiler. Use one wrench to prevent the From gas supply From gas supply boiler gas line connection from turning.
  • Page 57 series boiler manual insTallaTion 725/850 Check Natural or LP Gas Supply Pressure Figure 45 Gas line tapping Purge all air from the gas supply piping Check the boiler and its gas connection for leaks before placing the boiler in operation a Close manual main shutoff valve during any pressure testing at less than 14"...
  • Page 58 insTallaTion series boiler manual 725/850 Gas Piping, continued Pipe Sizing for Natural Gas Table 11 Pipe capacity for natural gas Size gas supply piping from meter outlet to Gas Supply Pipe Capacity (cubic feet per the entrance of the boiler in accordances with Gas Pipe hour) @ 0 .30"...
  • Page 59 series boiler manual eleCTriCal 725/850 SeCTion 3 Electrical This section is intended to provide wiring and zoning Wiring must be N E C Class 1 If original wiring instructions for qualified installers and service supplied with the boiler must be replaced, use only contractors type 105°C wire or equivalent The boiler must be electrically grounded as required by the National...
  • Page 60 Electrical - General, continued Power Requirements Figure 47 Terminal block locations • The SVF 725-850 boilers are manufactured for 120 VAC, 60 Hz electrical service • The total operating amperage indicated on the nameplate requires less than 10 Amps at full load •...
  • Page 61 series boiler manual eleCTriCal 725/850 Field Wiring The figures below show the high and low voltage terminal block wiring used in this section. Also refer to the schematic and ladder diagrams, Figure 50, page 62 and Figure 51, page 64 Figure 48 High voltage (TB2) terminal block wiring Figure 49 Low voltage (TB1) terminal block wiring section...
  • Page 62 eleCTriCal series boiler manual 725/850 Field Wiring, continued Schematic Diagram Figure 50 Schematic wiring diagram for SVF boilers (continued on the next page) To Start Interlock Device 120 VAC Power for boiler 120 VAC 120 VAC End Limit Ground (provide surge protection) Limit Circuits Auxiliary Devices Switch...
  • Page 63 series boiler manual eleCTriCal 725/850 Schematic Diagram, continued Frame Ground Analog Analog System Outdoor Night Boiler to Modbus Wireless Input Output Supply Setback Thermostat Aquastat/ Air Temp. External Boiler Cable From Outdoor Air (4-20mA) (4-20mA) Sensor Device Cable Temp Sensor Sensor Sensor Devices...
  • Page 64 eleCTriCal series boiler manual 725/850 Field Wiring, continued Ladder Diagram Figure 51 Ladder wiring diagram for SVF boilers (continued on the next page) 120 vac This symbol indicates connector pin number. See Schematic Wiring for connector identification. Fuse ON/OFF Circuit Service Switch Breaker 5A...
  • Page 65 series boiler manual eleCTriCal 725/850 Ladder Diagram, continued ification. 725/850 Ladder Wiring Diagram Electrical shock hazard — can cause severe injury or death. Disconnect power before installing or servicing. All contacts shown without power applied. Indicates items not provided Indicates Factory Installed Jumpers, Remove Factory Jumpers if Using.
  • Page 66 eleCTriCal series boiler manual 725/850 Field Wiring, continued A . Power Supply — REQUIRED • HOT L1 - Connect the hot lead of the 120 VAC, 60 Hz electrical service to the TB2-1 terminal • NEUTRAL N1 - Connect the neutral lead of Service Switch the 120 VAC, 60 Hz electrical service to the...
  • Page 67 series boiler manual eleCTriCal 725/850 D . Air Damper Interlock (Closure Switch) – As needed for systems • The Air Damper Interlock on TB2-13 and START INTERLOCK #2 (Ext. Limit) TB2-14 terminals allow for proof of open end START INTERLOCK #2 (Ext. Limit) limit switch on a motorized air damper START INTERLOCK #1 (Ext.
  • Page 68 eleCTriCal series boiler manual 725/850 Field Wiring, continued F . Relay A, B, C, and D (120 VAC Pilot Duty Dry Contacts) – As needed for systems WARNING External power supplies are required for Relays A, B, C, and D. Power is still present when the appliance is turned off.
  • Page 69 series boiler manual eleCTriCal 725/850 H . Enable/Disable (CH TT Input) – As needed for systems • Contact closure enables comfort heat Thermostat operation Device ENABLE / DISABLE [User Define] (CH TT) • Open circuit disables comfort heat operation ENABLE / DISABLE [User Define] (CH TT) 220008 I .
  • Page 70 eleCTriCal series boiler manual 725/850 Field Wiring, continued L . DHW Stat or Sensor – As needed for systems • TB1-9 and TB1-10 can be used to connect either an aquastat or remote DHW temperature sensor installed in a domestic hot water storage tank DHW Stat •...
  • Page 71 series boiler manual eleCTriCal 725/850 O . 4-20mA Analog Output – As needed for systems • TB1-15 and TB1-16 provide a 4-20mA analog output signal, which tracks the boiler’s firing rate • When operating at full power (maximum firing rate), the boiler will provide a 20mA output Modulating Output ›...
  • Page 72 eleCTriCal series boiler manual 725/850 Field Wiring, continued R . MODBUS Com A, B, and Shield – As needed for systems • TB1-22, TB1-23, and TB1-24 can be used to integrate the boiler with a Building Management System (BMS), Protocol Converter, or other device capable of RS-485 2-wire MODBUS ®...
  • Page 73 series boiler manual operaTion 725/850 SeCTion 4 Operation Figure 52 Local Representative screen This section is intended to provide instructions for control setup and boiler startup procedures State: Running Section Contents Control Setup and Operation Startup - Fill the System Startup - Final Checks Startup Procedure Control Setup and Operation...
  • Page 74 operaTion series boiler manual 725/850 Control Setup and Operation, continued Information Screen Figure 54 Information screen The Information screen (Figure 54) contains real-time, read-only values such as temperatures and relay states This screen is helpful in determining the operating characteristics Slide up or down on the touchscreen to scroll through the Information screen Setup Wizard The Setup Wizard is recommended for all boilers...
  • Page 75 series boiler manual operaTion 725/850 High Altitude Fan Speed Setup Figure 56 All Parameters and Boiler Settings screens WARNING Do not adjust the ignition RPM or other fan settings except as outlined in this section. High altitude installation will require ignition RPM adjustment based on Table 14, page 107.
  • Page 76 operaTion series boiler manual 725/850 Control Setup and Operation, continued High Altitude Fan Speed Setup, continued b Press <Reset Controller> and answer the pop-up question Once the fan speeds are adjusted, there are c Press <Home> and <Settings>, respectively certain, critical parameters that require parameter d Next, press <Verification>...
  • Page 77 series boiler manual operaTion 725/850 Control Panel Figure 60 Control panel and power switch location Once the boiler has been installed according to this manual, it is necessary to open the front door of the boiler in order to access the power (on/off) switch. The switch is located in the upper left-hand corner of the control panel as shown in Figure 60 WARNING...
  • Page 78 operaTion series boiler manual 725/850 Control Setup and Operation, continued Sequence of Operations Figure 62 Ignition sequencing timing WARNING IGNITION SEQUENCE TIMING If any manual reset limit device trips, DO NOT BLOWER reset without determining and correcting the GAS VALVE cause.
  • Page 79 Softened water must NOT be used without b See the Parts section starting on page 111 for Sentinel X100 as boiler corrosion may occur Weil-McLain part numbers to obtain cleaning Hardness must be less than 7 grains agents through a WM Technologies distributor...
  • Page 80 See the Parts section starting antifreeze container on page 111 for Weil-McLain part numbers to obtain Calculate the total volume (gallons) of all system antifreeze through a WM Technologies distributor piping and components, including the expansion...
  • Page 81 Add additional inhibitor if necessary annually The pH of the water mixture must be See manufacturer instructions or www weil-mclain between 7 0 and 8 5 Alternately, use the Sentinel to determine how much inhibitor to use inhibitor test kit to check concentration...
  • Page 82 operaTion series boiler manual 725/850 Startup - Final Checks Check for Gas Leaks Figure 63 Test port cap removal Before starting the boiler, and during initial operation, use a leak detector or smell around the boiler and floor for gas odorant or any unusual odor. Remove the boiler jacket door and smell the interior of the boiler jacket WARNING...
  • Page 83 series boiler manual operaTion 725/850 Figure 64 Operating instructions, warning FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is C.
  • Page 84 operaTion series boiler manual 725/850 Startup - Final Checks, continued Inspect the Pressure Switch Hoses Figure 65 Pressure switch tube locations Inspect all pressure switch sense hoses and verify 3.25" Flue Switch 0.11" Paired Switches 0.11" Wind Detection Switch Above control on the left panel Below control to the left Above control to the left correct installation See Figure 65 and Figure 66...
  • Page 85 series boiler manual operaTion 725/850 Startup Procedure Starting the Boiler Table 13 Acceptable combustion values Apply power to the boiler via the service switch High Fire Low Fire Fuel Follow the operating instructions on page 83 % CO CO ppm % CO CO ppm If this is the first time powering the boiler, refer to...
  • Page 86 operaTion series boiler manual 725/850 Startup Procedure, continued Check Flame and Combustion, continued Figure 67 Throttle and offset regulating screws Low Fire Check: Offset Adjustment Offset Adjustment 10 Use the control display to navigate to Manual Control Firing Rate and force the rate to 0% (low fire).
  • Page 87 series boiler manual operaTion 725/850 Gas Valve Adjustment, continued reading This may take a few minutes 18 Continue until the desired CO value is achieved High fire adjustment: 19 Confirm that the CO is within the limits in Table 13, page 85 IMPORTANT 20 Reinstall the T40 Torx head cap when adjustment is complete...
  • Page 88 operaTion series boiler manual 725/850 Startup Procedure, continued Check the System for Leaks Ensure both test harness rocker switches are in the ON position WARNING WARNING The system must be sealed gas-tight to prevent flue gas spillage and carbon monoxide DO NOT connect a manometer to the manual or emissions.
  • Page 89 series boiler manual operaTion 725/850 Verification Check List ‰ Verified that the control is programmed correctly? ‰ For multiple zones, adjusted for correct flow in ‰ Verified that the boiler and heat distribution units each zone? are filled with water? ‰...
  • Page 90 operaTion series boiler manual 725/850 This page intentionally left blank 550-100-290/0124...
  • Page 91 series boiler manual mainTenanCe 725/850 SeCTion 5 Maintenance Preventative measures include the following: This section is intended to provide maintenance instructions and timing for the boiler • Avoid breathing in dust • Wear long-sleeved, loose fitting clothing, gloves, Section Contents and eye protection •...
  • Page 92 mainTenanCe series boiler manual 725/850 Annual Inspection First-Year Special Inspection Obtain a Boiler Annual Maintenance Kit (part number d Make sure there is no blockage or accumulation 384-000-379) before attempting the first-year of debris in the burner or burner ports Replace inspection to ensure all needed parts are available the burner if necessary This kit includes a heat exchanger cover plate...
  • Page 93 series boiler manual mainTenanCe 725/850 General Information WARNING The boiler should be inspected and started at the beginning of the heating season annually, only by a Jacket door gaskets must be intact and must qualified service technician. provide a reliable seal. Failure to comply can The maintenance and care of the boiler designated result in severe personal injury, death, or on page 94, and explained on the following...
  • Page 94 mainTenanCe series boiler manual 725/850 Annual Inspection, continued Service and Maintenance Schedules Service Technician Owner Maintenance (use this manual for instructions) (see the User Manual for instructions) General: ‰ Check the boiler area ‰ Investigate reported issues ‰ Check air openings ‰...
  • Page 95 series boiler manual mainTenanCe 725/850 Annual Startup Check Air Openings b Make sure the vents do not leak c Replace any leaking vents Verify that combustion and ventilation air Check the system water chemistry See page 79 openings to the boiler room and building are open Check the Boiler Relief Valve and unobstructed Check operation and wiring of automatic...
  • Page 96 mainTenanCe series boiler manual 725/850 Annual Startup, continued Check the Expansion Tank too small, add one or more additional tanks as necessary to provide sufficient expansion. If the Expansion tanks provide space for water to move tank size is large enough, remove the tank from in and out as the heating system water expands or the system and check charge pressure If the tank contracts due to temperature increases or decreases...
  • Page 97 series boiler manual mainTenanCe 725/850 Inspect the Flame Sense Rod and Wiring Figure 68 Boiler interior assembled view Disconnect the flame sense wire connected to the flame sense rod. See item 9 in the figures on this page Use a 3 mm Allen wrench to remove the two screws securing the flame sense rod assembly to the heat exchanger cover plate Carefully remove the flame sense rod.
  • Page 98 mainTenanCe series boiler manual 725/850 Annual Startup, continued Inspect and Clean the Burner Inspect the burner exterior It must be in good condition with no visible damage WARNING Clean the underside of the burner flange with The boiler contains ceramic fiber materials. a soft brush to remove any remaining gasket Use care when handling these materials per fragments...
  • Page 99 series boiler manual mainTenanCe 725/850 Cleaning the Heat Exchanger - Water Side In order for the efficiency of boilers to increase Disconnect the blower from the cover plate with a beyond the condensing limit, new materials have 13 mm wrench or socket Carefully lift the blower, been introduced for the heat exchanger, including mixer, and gas valve assembly out of the boiler stainless steel Stainless steel has excellent heat...
  • Page 100 mainTenanCe series boiler manual 725/850 Annual Startup, continued Reinstall All Components Figure 70 Cover plate and gasket installation See the figures on page 97, Figure 70, and Figure 71, page 101 for the references below Place the cover plate onto the heat exchanger Ensure the blower flange is facing the front of the boiler and square Install all bolts finger-tight from the heat...
  • Page 101 series boiler manual mainTenanCe 725/850 Figure 71 Cover plate nut tightening sequences • Gradually tighten the cover plate and burner plate access bolts in the sequence shown in the illustration • Burner torque: 44 in-lbs (5 Nm), 10 mm wrench •...
  • Page 102 mainTenanCe series boiler manual 725/850 Annual Startup, continued Inspecting the Pressure Switches Replacing the Pressure Switches Inspect the pressure switches Ensure the wire Refer to Figure 72 for the instructions in this section connects are properly connected and the tubes are secured to the pressure ports Inspect the tubes for 1 .
  • Page 103 series boiler manual mainTenanCe 725/850 Replacing the Pressure Switches, continued f Remove the two screws holding the bracket to the control tray 3 . Wind detection switch (WDS): g Install the new WDS with two new screws a Remove the jumper wire from the NC terminal h Reconnect the WDS to the 4-way connector of on the WDS and the common terminal on the the paired MAF switches...
  • Page 104 mainTenanCe series boiler manual 725/850 Annual Startup, continued Check Boiler Wiring Low Water Cut-Off Test Inspect all boiler wiring Make sure the wires are The boiler is furnished with a probe-type low water in good condition and securely attached cut-off (LWCO). The probe is installed on the heat Verify that all connectors are securely inserted exchanger in order to detect the presence of water at Verify that the ground wires are connected to the...
  • Page 105 series boiler manual mainTenanCe 725/850 Check the Burner Flame Check the Flame Signal WARNING Check the flame signal at both high and low fire. The boiler contains ceramic fiber materials. a Touch the INFO button in the lower corner of the display to load the Information menu This Use care when handling these materials per instructions on page 91.
  • Page 106 mainTenanCe series boiler manual 725/850 Annual Startup, continued Check the Flue Gas Temperature High Altitude Set the boiler to high fire. The boiler will automatically derate the BTU values Adjust the control display to view flue gas listed in Table 14, page 107 at altitudes over temperature and boiler return temperature 2,000 ft above sea level The flue gas temperature should be no more than...
  • Page 107 series boiler manual mainTenanCe 725/850 Table 14 Natural gas (NG) and propane (LP) firing rates and corresponding blower speeds (low fire and high fire), for altitudes up to 2,000 ft (default settings), and for high altitudes (above 2,000 ft ) Low Fire Model and 725 NG...
  • Page 108 mainTenanCe series boiler manual 725/850 Annual Startup, continued Manual Test Mode Reinstall the Jacket Door After Servicing Single Boiler: Reinstall the boiler jacket door after startup or servicing The boiler front door, side panel, and top Navigate to the Manual Control Firing Rate panel must all be securely fastened to the boiler to screen under the INFO/Service menu prevent the boiler from drawing air from inside the...
  • Page 109 series boiler manual TroubleshooTing 725/850 SeCTion 6 Troubleshooting This section is intended to provide solutions by troubleshooting various issues with the boiler See Automatic reset lockouts This lockout resolves the SVF Advanced Manual for complete information with a self-reset when the error condition clears Section Contents Loss of Power Troubleshooting - General...
  • Page 110 TroubleshooTing series boiler manual 725/850 Errors and Lockouts, continued High Water Temperature Flame Failure When the boiler water has exceeded both the In the event of a flame failure, the control may display operating temperature limit and the manual reset high one of the following error messages temperature limit, the control will display 10009: "High •...
  • Page 111 384000392 Kit - Service Annual Maintenance Kit: (electrode igniter, flame sense rod, insulation, gaskets, fasteners) 384000379 Conversion Kit, Natural Gas to LP, SVF 725/850 (venturi, venturi gasket, O-ring, LP orifice, hardware, instructions) 384000380 *PROPANE (LP) DESIGN AVAILABILITY PENDING* Kit - Service Automatic Air Valve...
  • Page 112 parTs series boiler manual 725/850 The SVF Commercial Condensing Water Boiler Legend for Figure 73, page 113 1 . Stainless steel heat exchanger 20 . Flame inspection windows 99 88 square ft of surface for heat transfer SA-240 stainless steel, Quartz glass windows provide a view of the burner surface and flame.
  • Page 113 series boiler manual parTs 725/850 Figure 73 The SVF commercial condensing water boiler Electrical Panel Components Components - Top View Components - Back View Components - Front View 220069 550-100-290/0124...
  • Page 114 parTs series boiler manual 725/850 Replacement Parts Table 16 Jacket parts and numbers for Figure 74, page 115 Item Description Part Number Kit – Service Caster 384000226 Kit – Service Leveling Leg Kit 384000227 Kit – Service Panel Side 384000329 Kit –...
  • Page 115 series boiler manual parTs 725/850 Figure 74 Jacket parts 550-100-290/0124...
  • Page 116 parTs series boiler manual 725/850 Replacement Parts, continued Table 17 Kits and part numbers for Figure 75, page 117 Item Description Part Number Kit – Service Cover Plate 384000343 Kit – Service Door Flap 384000344 Kit – Service Cover Plate, Top 384000345 Kit –...
  • Page 117 series boiler manual parTs 725/850 Figure 75 Combustion, condensate 220065 550-100-290/0124...
  • Page 118 parTs series boiler manual 725/850 Replacement Parts, continued Table 18 Control parts and part numbers for Figure 76, page 119 Item Description Part Number Kit – Service LWCO Probe 384000357 Kit – Service Water Temperature Sensor + High Limit 384000358 Kit –...
  • Page 119 series boiler manual parTs 725/850 Figure 76 Controls, sensors 220070 550-100-290/0124...
  • Page 120 3 3-in-1 air intake adapter, 6" 7 Condensate drain tube 4. 3-in-1 flue adapter, 6" 8 Control SVF 725/850 DIMENSIONS (inches) - height dimensions given are based on casters resting on the ground . Add lifted boiler measurements to height dimensions accordingly . 33-3/8 49-13/16...
  • Page 121 Manifold Combustion Air Total CSA Input Boiler H .P . Net Water Rating Heating Capacity Duct Size Boilers in System Output, Square Input, MBH Inches SVF 725 SVF 850 Note 1 Note 2 1450 1416 42 3 1232 1700 1658 49 5...
  • Page 122 Weight Weight Weight (Note 1) (Note 1) (Note 1) (Note 1) (Note 2) (Note 3) (Note 4) (Note 5) (no water) (filled) SVF 725 725,000 72500 72500 708,000 616,000 97 7 16 5 SVF 850 850,000 72500 72500 829,000 721,000...
  • Page 123 series boiler manual serviCe informaTion 725/850 Maintenance Log High fire / Stack Date Action Technician Low Fire Temp 550-100-290/0124...
  • Page 124 serviCe informaTion series boiler manual 725/850 Installation and Service Certificate Boiler Model: Series: Consumer Protection Number (CP): Date Installed: BTU Input: ‰ Installation instructions have been followed ‰ Checkout sequence has been performed ‰ Above information is certified to be correct. ‰...
  • Page 125 series boiler manual serviCe informaTion 725/850 Notes 550-100-290/0124...
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  • Page 128 WM Technologies, LLC 500 Blaine Street Michigan City, IN 46360-2388 Telephone: (800) 654-2109 weil-mclain.com Manual Part Number 550-100-290/0124...

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