Weil-McLain SVF Series 1 Manual
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Weil-McLain SVF Series 1 Manual

Weil-McLain SVF Series 1 Manual

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Boiler Manual
Th is manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including 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.
DO NOT operate the boiler during construction
free area. Th e boiler can be severely damaged by drywall dust or other combustion air contaminants.
Models 750 - 1100
Commercial Condensing
'
• Installation
• Startup
unless combustion air is piped to the boiler air inlet from a dust-free and contaminant-
Series 1
• Maintenance
• Parts
Part number 550-100-200/1018

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Summary of Contents for Weil-McLain SVF Series 1

  • Page 1 Series 1 Models 750 - 1100 Commercial Condensing Boiler Manual • Installation • Maintenance • Startup • Parts Th is manual must only be used by a qualifi ed heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing.
  • Page 2 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Commercial Condensing Water Boiler Stainless steel heat exchanger Control overview Heat exchanger stainless steel vertical helical tube. • The control can operate a single boiler or coordinate with other Burner/Heat exchanger cover plate SVF 750-1100 Series 1 boilers in a multiple boiler system.
  • Page 3 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Commercial Condensing Water Boiler Electrical panel components Components - Top View SVF-1100 top view SVF-1100-Fr Elec Components - Back View Components - Front View B A C K SVF-1100-B SVF-1100-F Part number 550-100-200/1018...

  • Page 4: Table Of Contents

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Contents Contents ....4 DO NOT START THIS BOILER without Hazard definitions .

  • Page 5: Please Read Before Proceeding

    See the instructions at right. contact with water, replace the boiler with a new Weil-McLain boiler. Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

  • Page 6: Prepare Boiler Location

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location Installations must comply with: 4. Foundation may be of wood, brick or concrete (minimum 2 inches thick) construction. • Local, state, provincial, and national codes, laws, regulations and 5.
  • Page 7 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location (continued) Openings in floors, walls, ceilings or roofs must be Clearance requirements designed for fire stopping as required by local codes. Vent pipe openings through combustible materials Clearances from combustible materials must be 3/8”...
  • Page 8 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler location (continued) Verify that boiler placement and clearances comply with all applicable codes. Placing multiple boilers 1. Locate multiple boilers in boiler room to provide at least the minimum clearances 4.

  • Page 9: Prepare Boiler

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler Provide air openings to room Air openings — General Direct exhaust installations — On direct Follow the National Fuel Gas Code - ANSI Z223.1/NFPA54 – latest exhaust installations, the boiler draws combustion edition (U.S.) or Natural Gas and Propane Installation Code - CAN/ air from the boiler room.
  • Page 10 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) 1. See Figure 4 for the following. Cold weather handling — If boiler has been stored in a 2. Move the crate to a solid, level surface. very cold location (below 32°F) before installation, handle with astic components come to room temperature.
  • Page 11 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) Placing the boiler Figure 5 Removing the casters to allow bolting the boiler to mounting blocks 1. Roll the boiler down the ramp and move the boiler into position. 2.

  • Page 12: Propane Conversion Procedure

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Prepare boiler (continued) 5. Disconnect gas valve and pressure switch harnesses. 6. Remove the ball valve assembly Prepare boiler for propane a. Remove the four (4) M5 bolts attaching the ball valve flange (when required) to the gas valve with a 4mm Allen wrench.
  • Page 13 8. Make sure that constant gauge pressure has been maintained throughout test. 9. Check for leaks. Repair any leaks from threaded joints. If leaks are found in Heat Exchanger, please consult your Weil-McLain representative. 10. Slowly release pressure and drain.

  • Page 14: Install Water Piping

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping Use two wrenches when tightening water piping at boiler, Backflow preventer using one of the wrenches to prevent the boiler interior 1. Use backflow check valve in water fill as required by local piping from turning.
  • Page 15 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping (continued) DO NOT design for flow rates above or below the range listed in Figure  10. The boiler and system components can be damaged by excessive or insuf- Recommended pipe sizing ficient flow.
  • Page 16 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Install water piping (continued) Expansion tank and make-up water Figure 11 Expansion tank piping — diaphragm-type expansion tank 1. Ensure expansion tank size will handle boiler and system water volume and temperature.
  • Page 17 Assign DHW and Space heating to same Priority. Do not use outdoor reset for this application. 3. For more than 3-zones, use Weil-McLain WMZV zone valve controller. Controlling the circulators Space Heating Connect zone valve end switches to a 1.
  • Page 18 No Priorities – Space heating and DHW can occur simultaneously at same Supply Max. temperature. Use only if DHW is a zone in 3. For more than 3-zones, use Weil-McLain WMZV zone valve controller. system. Assign DHW and Space heating to same Priority. Do not Connect zone valve end switches to a Space Heating use outdoor reset for this application.
  • Page 19 DHW Priority applications. and three others). Refer to Field wiring, beginning on page 53, for instructions on wiring to circulators. The boiler circulator cannot 3. For more than 3-zones, use Weil-McLain WMCR zone Circ be used for a zone pump. controller.
  • Page 20 Priorities 1 and/or 2 for space heating; Priority 3 for DHW. The for DHW Priority applications. control will not run multiple priorities simultaneously. 3. For more than 3-zones, use Weil-McLain WMCR zone Circ c. No Priorities – Space heating and DHW can occur simultaneously controller.
  • Page 21 DHW performance. Some local codes may require double-wall DHW heat exchanger design. Use only the an- tifreeze listed by Weil-McLain for use with this boiler. See page 105 for details. Chilled medium, if used, is piped in parallel with heating boiler as shown in Figure 17.

  • Page 22: Venting/Air Piping - Massachusetts Installations

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/air piping — Massachusetts installations Venting instructions for the installations in the Commonwealth of Massachusetts (a) For all sidewall horizontally-vented gas-fueled equipment installed . The state or local gas inspector of the side INSPECTION wall horizontally vented gas fueled equipment shall not ap- in every dwelling, building or structure used in whole or in part...

  • Page 23: Venting/Combustion Air - General

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — general There are two venting Method 1: Direct exhaust Method 2: Direct vent methods available. • Combustion air taken from inside • Combustion air piped to boiler from Follow the instructions (no air piping connected to air intake) outside...
  • Page 24 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — general (continued) Combustion air contamination Direct exhaust (combustion air from boiler room): Direct vent (combustion air piped from outside): a. Provide combustion air openings to boiler room as described a.

  • Page 25: Venting/Combustion Air - Options (Category Ii & Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — options (Category II & IV) Figure 19 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes Items Material...

  • Page 26: Appliances Remaining On An Existing Vent System

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Appliances remaining on an existing vent system Existing vent test procedure Do not install the SVF boiler into a common (The following is intended to test whether the vent with any other appliance.

  • Page 27: Venting/Combustion Air - Options (Category Ii)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — options (Category II) Category II Requirements In addition to the SVF boilers Category IV rating (positive pressure, for SVF boilers installed in a Category II configuration. The likely to condense), SVF boilers are approved for Category II (nega- carbon monoxide detector must be wired on the same electrical...
  • Page 28 Weil-McLain recommends the use of a Variable Speed Chimney Fan / Power venter to ensure that the appropriate negative pressure range is kept for Category II venting. The reason this may be needed is due to the higher effi- ciency of the boiler.
  • Page 29 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Venting/combustion air — options (Category IV) Figure 21 SVF boiler venting and air piping — OPTIONS and PIPING LIMITS — The table below lists the acceptable vent/air pipe terminations described in this manual. USE ONLY the pipe materials listed in Figure 19, page 25 Boiler vent and air connections: The SVF boiler uses a 3- in 1 adapter vent/air connection.

  • Page 30: Direct Exhaust - Boiler Room Air Openings (Category Ii And Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings (Category II and IV) Special considerations Combustion air provision The SVF Commercial boiler can use inside air if no contaminants are Tight construction present in the boiler space.
  • Page 31 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Boiler room air openings (continued) (Category II and IV) Figure 22 MINIMUM combustion air openings for direct exhaust applications — ALL OPENING SIZES ARE FREE AREA Air openings boiler boiler...

  • Page 32: Direct Exhaust - Vertical (Category Ii And Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Vertical (Category II and IV) Figure 23 Vertical direct exhaust termination Use only the vent materials and kits listed in Figure 19, page 25 Read and follow all instructions in this manual.

  • Page 33: Direct Exhaust - Sidewall Termination Location (Category Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall Termination location (Category IV) Figure 24 DIRECT EXHAUST INSTALLATIONS — Requirements for termination location — clearances and placement Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent buildings, openable windows and building openings shall not be less than those values specifi ed in the National Fuel Gas Code - ANSI Z223.1/ NFPA 54 –...

  • Page 34: Direct Exhaust - Sidewall (Category Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall (Category IV) Figure 25 Sidewall direct exhaust termination Use only the vent materials and kits listed in Figure 19, page 25 Read and follow all instructions in this manual.
  • Page 35 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT EXHAUST — Sidewall (continued) (Category IV) 2. Vent pipe penetration: Figure 26 Multiple boiler direct exhaust sidewall a. Cut a hole for the vent pipe. terminations (see Figure 25, page 34 for b.

  • Page 36: Direct Vent - Boiler Room Air Openings (Category Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Boiler room air openings (Category IV) Exhaust fans and air movers Combustion/ventilation air provision The appliance space must never be under a negative pressure unless all appliances are installed as direct vent.
  • Page 37 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Boiler room air openings (continued) (Category IV) Figure 29 MINIMUM combustion air openings for direct vent applications — ALL OPENING SIZES ARE FREE AREA Air openings boiler boiler The required air opening sizes below are FREE AREA,...

  • Page 38: Direct Vent - Sidewall Termination Location (Category Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall Termination location (Category IV) Figure 30 DIRECT VENT INSTALLATIONS — Requirements for termination location — clearances and placement Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent buildings, openable windows and building openings shall not be less than those values specifi ed in the National Fuel Gas Code - ANSI Z223.1/ NFPA 54 –...

  • Page 39: Direct Vent - Sidewall (Category Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall (Category IV) Figure 31 Sidewall direct vent terminations — vent and air Use only the vent/air materials and kits listed in Figure 19, page 25 Read and follow all instructions in this manual.
  • Page 40 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Sidewall (continued) (Category IV) 3. Vent pipe penetration: Figure 32 Multiple terminations — clearance from vent a. Cut a hole for the vent pipe. of one to air intake of the next (normal and snorkel layouts).

  • Page 41: Direct Vent - Vertical (Category Iv)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical (Category IV) Figure 34 Vertical direct vent terminations (air termination can be vertical or sidewall as shown below). Use only the vent/air piping materials and kits listed in Figure 19, page 25 Read and follow all instructions in this manual.
  • Page 42 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical (continued) (Category IV) Install vent and air ter minations Figure 36 Vertical vent and air terminations. 1. Air pipe penetration a. Cut a hole for the air pipe, sized per the vent/air pipe manufacturer’s instructions.
  • Page 43 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIRECT VENT — Vertical (continued) (Category IV) Figure 37 Termination location — multiple boilers — vertical vent/sidewall air. VENT PIPING (through roof) AIR PIPING (sidewall) Multiple boiler applications —...

  • Page 44: Install Condensate Components

    Condensate trap assembly, installed cally with a pH from 3.2 to 4.5). Install a neutralizing filter if required by local codes. See Replacement parts section at the end of this manual for a Weil-McLain condensate neutralizer kit. Figure 39 Condensate pump capacity, GPH...

  • Page 45: Gas Piping

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Gas piping Connecting gas supply piping Use two wrenches when tightening gas piping at boiler , using one wrench to prevent the 1. Connect gas supply piping to the boiler, see Figure 42 . boiler gas line connection from turning.

  • Page 46: Gas Train Diagram

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Gas piping (continued) Pipe sizing for Natural Gas Figure 44 Pipe capacity for natural gas 1. Size gas supply piping from meter outlet to entrance of boiler in accordance with Figure 44 and Figure 45.

  • Page 47: Field Wiring (See Figure 57 & Figure 58)

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48 ) Wiring must be N.E.C. Class 1. If original wiring For your ELECTRICAL SHOCK HAZARD — as supplied with boiler must be replaced, use safety, turn off electrical power supply at service only type 105 °C wire or equivalent.
  • Page 48 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring Schematic Diagram (continued) Figure 47 Schematic wiring diagram — boilers (continued on next page) Part number 550-100-200/1018...
  • Page 49 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring Schematic Diagram (continued) Figure 57 (continued from previous page) Schematic wiring diagram — boilers Part number 550-100-200/1018...
  • Page 50 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring Ladder Diagram (continued) Figure 48 Ladder wiring diagram — boilers (continued on next page) Part number 550-100-200/1018...
  • Page 51 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring Ladder Diagram (continued) Figure 48 (continued from previous page) Ladder wiring diagram — boilers Part number 550-100-200/1018...
  • Page 52 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48) (continued) A. 120 VAC Power Supply – REQUIRED Terminal Block P1 1. Boiler line voltage power — Boiler loads are listed below. Provide and install a fused disconnect or service switch as required by applicable codes.
  • Page 53 Primary / secondary piping is recommended to be used with the SVF boiler to ensure proper flow through the heat exchanger. Other designed piping arrangements will work as long as water flow requirements are met from page 15, contact your local Weil-McLain commercial representative for assistance. See Figure 47, page 48 for details D.
  • Page 54 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48) (continued) E. System supply and return temperature sensors – REQUIRED Terminal Block P14 #1 & #2 1. Two (2) immersion temperature sensors are shipped with each boiler. Install one to the system supply piping and the other to the system return piping.
  • Page 55 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48) (continued) G. External limits – OPTIONAL To cause MANUAL reset: Terminal Block P13 #1 & #2 control will require manual reset after circuit is interrupted 1.
  • Page 56 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48) (continued) I. Closure switch (flow switch and/or CAD) – OPTIONAL Jumper on Terminal Strip P11 1. A flow switch or combustion air damper (CAD) interlock can be configured by removing jumper.
  • Page 57 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48) (continued) K. 0 –10 VDC Remote TARGET input – OPTIONAL Terminal Block P15 #5 & #6 1. See illustration at right and Figure 47, page 48 (wiring diagram) for details. 2.
  • Page 58 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48) (continued) L. 0–10 VDC Remote MODULATION input – OPTIONAL Terminal Block P15 #5 & #6 ( control module, left side) Using an external multiple boiler controller —...
  • Page 59 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Field wiring (see Figure 47 & Figure 48) (continued) M. Multiple Boiler and BMS Connections – see ADVANCED Manual Terminal Strips EP11 and E P12 on Expansion Module (Expansion module, right side) 1.

  • Page 60: Zoning With The Svf

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Zoning with the Control A. Zoning with CIRCULATORS, suggested applications Three space heating zones (no DHW) 1. Review wiring information on page 49 (120VAC outputs) and page 53 (24VAC inputs). 2.
  • Page 61 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Zoning with the Control (continued) B. Zoning with ZONE VALVES, suggested applications Two space heating zones (no DHW) 1. Review wiring information on page 49 (120VAC out- puts) and page 53 (24VAC inputs). 2.

  • Page 62: Control Operation And Setup

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup Figure 49 Control sequence of operation Control setup 1. Set control parameters using the WIZARD option provided on initial Display start-up or manually enter parameters using control menus (see Fig- Control action status ure 56, page 68 and following pages for information.)
  • Page 63 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) Control Priorities & Input/Outputs Setting Up the Boiler • For heating installations with multiple systems, the Control uses • DETERMINE input/output needs – PRIORITIES to determine the order of operation of the systems.
  • Page 64 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) Outdoor reset operation Figure 50 Outdoor reset operation 1. Set desired temperatures for space heating zones. 2. For an explanation of the target temperatures and associated outdoor temperatures, see Figure 50.
  • Page 65 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) Figure 52 SVF single boiler essential settings (REQUIRED on initial start-up) — see page 67 for explanation Part number 550-100-200/1018...
  • Page 66 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup Control operation and setup (continued) (continued) Figure 53 SVF control display screens and typical navigation Part number 550-100-200/1018...
  • Page 67 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Control operation and setup (continued) Figure 54 SVF control settings available in BASIC MODE (see Advanced Manual for ADVANCED MODE settings) Available settings from CONTRACTOR MENU Boiler Settings Menu Priority 2 menu Assign Inputs menu •...

  • Page 68: Contractor Menus

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER CONTRACTOR menus 1. Access contractor menus by pressing and holding the UP and Boiler Model, Altitude and Fuel Type are criti- DOWN arrow keys at the same time for 7 seconds. cal settings.

  • Page 69: Boiler Settings Menu, Basic Mode

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER BOILER SETTINGS menu, BASIC mode 1. Access contractor menus by pressing and holding the UP and Boiler Model, Altitude and Fuel Type are criti- DOWN arrow keys at the same time for 7 seconds. cal settings.

  • Page 70: Priority 1, 2, 3 Menus, Basic Mode

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER PRIORITY 1, 2, 3 menus, BASIC mode 1. Access contractor menus by pressing and holding the UP and Boiler Model, Altitude and Fuel Type are criti- DOWN arrow keys at the same time for 7 seconds. cal settings.

  • Page 71: Assign Inputs Menu, Basic Mode

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER ASSIGN INPUTS menu, BASIC mode 1. Access contractor menus by pressing and holding the UP and Boiler Model, Altitude and Fuel Type are criti- DOWN arrow keys at the same time for 7 seconds. cal settings.
  • Page 72 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER ASSIGN INPUTS menu, BASIC mode (continued) Figure 60 AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 59, page 71) Option Activation conditions Suggested uses • Hot loop for seasonal boilers that are manually ALWAYS ON •...

  • Page 73: Diagnostic Menu

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTIC menu Figure 62 DIAGNOSTICS menu navigation (see Figure 53, page 66 for access information) Menus Next screen Next screen Next screen Next screen Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS TEMPERATURES STATUS:...
  • Page 74 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 63 DIAGNOSTICS menu navigation, continued (see Figure 63, page 74 for access information) Menus Next screen Next screen Next screen Next screen Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS (cont.) NETWORK INPUTS Shows input status of all network boiler inputs.
  • Page 75 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 64 DIAGNOSTICS menu details (see Figure 53, page 66 for access information) Menu/Item Comment Temperatures Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Status Warm Weather Shut down, Trouble Boiler Out1...
  • Page 76 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 65 DIAGNOSTICS menu details (continued) (see Figure 53, page 66 for access information) Menu/Item Comment Run Times Burner Time Displays cumulative time the burner has been active (can be increased by user) Records the days of operation passed from the last time the Master boiler rotated the firing sequence.
  • Page 77 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER DIAGNOSTICS menu (continued) Figure 66 DIAGNOSTICS menu details (continued) (see Figure 53, page 66 for access information) Menu/Item Comment Displays time that lockout occurred Time Date Displays date that lockout occurred Status Displays what the status of the boiler was at the time of the error Choose this to view the Boiler Temperatures at the time of the error...

  • Page 78: Maintenance, Date And Time Menus

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER MAINTENANCE, DATE AND TIME menus Figure 67 MAINTENANCE, DATE AND TIME menus — navigation (see Figure 53, page 66 for access information) Maintenance Info Comment Name Contractor name to appear in maintenance reminders and during lockouts Phone Contractor phone number Model...

  • Page 79: Startup - Fill The System

    1. If necessary, use an approved chemical cleaning agent, following McLain.com. the manufacturer’s guidelines for procedures. 2. See Replacement parts at the end of this manual for Weil-McLain a. A list of approved cleaning products is available at www. part numbers to obtain antifreeze through a Weil-McLain dis- Weil-McLain.com.
  • Page 80 Then check the inhibitor level. Add additional 13. Refill to correct pressure. inhibitor if necessary. 4. See separate instructions or Weil-McLain website for suggested Check/verify water chemistry guidelines to determine how much inhibitor to use. 1. The system may have residual substances that could affect water chemistry.

  • Page 81: Startup - Final Checks

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Startup — fi nal checks Check thermostat circuit(s) Figure 68 Pressure switch tube locations 1. Disconnect the two external wires connected to the boiler thermostat terminals (see instructions beginning on page 53 for terminal locations).

  • Page 82: Startup Procedure

    Installation Code, CAN/CSA B149.1. given in Figure 70, page 83. For elevations above 10,000 feet, please contact Weil-McLain Technical Support for details. SVF boilers are shipped ready to fire natural gas ONLY. In Canada, Input rates are derated 10% for altitudes You must install the propane conversion kit if the boiler of 2000 ft.
  • Page 83 . Re-install 10.00 < 60 9.50 < 60 1000 the cover screw when completed. 6. Consult your local Weil-McLain representative if acceptable results 1100 10.00 < 60 9.50 < 60 cannot be obtained for both high and low fi re.
  • Page 84 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Startup procedure (continued) 2. Use the Control display to navigate to Manual test mode Figure 72 Gas valve test pressure tapping (see Figure 63, page 74 ) and force the fi ring rate to Low (low fi re).
  • Page 85 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Startup procedure (continued) Figure 73 Operating instructions (WARNING — Verify that the control is set correctly before proceeding Part number 550-100-200/1018...

  • Page 86: Annual Startup And Maintenance Schedule

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup and maintenance schedule Figure 74 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) General: Investigate reported problems. •...

  • Page 87: Annual Startup

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup HANDLING CERAMIC FIBER FIRST-YEAR SPECIAL INSPECTION MATERIALS No later than 12 months after the boiler is installed, REMOVAL OF SIGHT GLASS GASKET perform a first-year inspection of the boiler. This must include the following in addition to routine annual The sight glass gasket in this product contains...
  • Page 88 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Check all piping for leaks The boiler should be inspected and started Eliminate all system or boiler leaks. Continual fresh annually, at the beginning of the heating make-up water will reduce boiler life.
  • Page 89 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Safety relief valves should be reinspected AT LEAST — tank is most likely waterlogged. Install a tank • Closed-type tank ONCE EVERY THREE YEARS, by a licensed fitting if not already installed.
  • Page 90 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Check all boiler wiring Figure 77 Gas pipe and air inlet hose removal Inspect all boiler wiring, making sure wires are in good condition and securely att ached.
  • Page 91 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Figure 80 Combustion chamber access cover removal d. Avoid dragging the fi ber mesh on any part of the boiler during removal. Caution when using a fl at blade screw driver to remove IMPORTANT —...
  • Page 92 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Annual startup (continued) Check flame signal Manual Test Mode for Single and Multiple Boilers 1. Navigate to Diagnostics/Inputs on the Control display (see Figure 62, page 73). Single Boiler 2. If the flame signal drops to less than 24 above the Shutdown values, 1.

  • Page 93: Troubleshooting

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting Before servicing and making connections . . . ELECTRICAL SHOCK HAZARD — The ALWAYS TURN POWER OFF TO THE boiler ON/OFF switch does not turn off all power BOILER TO PREVENT ELECTRICAL to the boiler.
  • Page 94 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Check the following: 5. Reinstall jacket top panel and boiler jacket door after checking 1. Space heating: the fuses. a. Make sure thermostat is calling for heat and contacts (includ- 6.
  • Page 95 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis. Control fault indications 1. The Control provides diagnostic information for both 2.
  • Page 96 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Figure 88 Troubleshooting suggestions for boilers RESET TO FACTORY DEFAULT 2. Reset to Factory Default can be found on the BOILER SET- 1. Selecting this will prompt the user to hold the enter button for TINGS menu, see Figure 57, page 69.
  • Page 97 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Figure 88 Troubleshooting suggestions for boilers (continued) Control Fault Displays, Diagnostics and Suggested Corrective Actions Display Condition Diagnostics Corrective Action(s) Nothing shown Control is not receiving 24V Check wiring for short circuit or Correct wiring per wiring diagram including connection of transformer on display...
  • Page 98 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Figure 88 Troubleshooting suggestions for boilers (continued) Control Fault Displays, Diagnostics and Suggested Corrective Actions Display Condition Diagnostics Corrective Action(s) LOW WTR Occurs if internal low water Automatic reset occurs if Check for low water condition in system.
  • Page 99 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Figure 88 Troubleshooting suggestions for boilers (continued) Display Condition Diagnostics Corrective Action(s) Occurs if manual or automatic Automatic external limit will Is there an external safety device connected? If yes, trouble shoot the LIMIT OPEN reset limit opens.
  • Page 100 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Troubleshooting (continued) Figure 88 Troubleshooting suggestions for boilers (continued) Display Condition Diagnostics Corrective Action(s) IGNITION Boiler went through 2 ignition Reset by using manual reset Check condensate trap for blockage allowing condensate to accumulate inside heat exchanger.
  • Page 101 flue-ways for abnormal wear and buildup. Manual reset is required if the temperature rises above 220°F. Inspect vent system for abnormal wear or damage. Reset using manual reset screen on display. Contact Weil-McLain Technical Support. Part number 550-100-200/1018...

  • Page 102: Maintenance

    “TSP. ” Weil-McLain recommends Sentinel X400 for cleaning boiler. See the Replacement Parts section at the end of this manual for ordering information.
  • Page 103 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Maintenance (continued) 4. Re-install gasket and reconnect the union of the gas pipe. Figure 89 Burner/heat exchanger cover plate gasket and 5. Reconnect the two (2) wire harnesses from the blower, cover plate re-installation the harness from the gas valve, and the harness from the gas pressure switches.
  • Page 104 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Maintenance (continued) Figure 90 Cover plate nut tightening sequences the cover Gradually tighten plate nuts in the sequence shown in Figure 90 until torque reaches 6 N-m/53 in-lbs/4.4 ft-lbs. If the tightening is not done as specified, the plate could buckle, allowing a flue gas leakage.

  • Page 105: Replacement Parts

    Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts Go to www.weil-mclain.com to locate Weil-McLain distributors Replacement parts must be purchased through a lo- Weil-McLain part numbers are found in Weil-McLain cal Weil-McLain distributor. When ordering, specify Boilers and Controls Repair Parts Lists.
  • Page 106 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Figure 92 Jacket parts Item Description Part Number 384-000-129 Jacket side (hardware) SVF 750 384-000-130 Jacket side (hardware) SVF 1000/1100...
  • Page 107 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Figure 93 Jacket parts Part number 550-100-200/1018...
  • Page 108 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Figure 94 Burner, blower, cover plate, venturi, gas train and miscellaneous Item Description Part Number Kit-Service Burner-Premix Fiber-Mesh SVF 750...
  • Page 109 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Figure 95 Burner, blower, cover plate, venturi, gas train and miscellaneous Part number 550-100-200/1018...
  • Page 110 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Go to www.weil-mclain.com to locate Weil-McLain distributors Figure 96 Controls Item Description Part Number Display housing with LCD SVF 750/1000/1100 384-000-155 Expansion module 120 Volt...
  • Page 111 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Replacement parts (continued) Figure 97 Controls Part number 550-100-200/1018...

  • Page 112: Dimensions

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Dimensions Figure 98 Dimensional data — LEGEND Supply connection, 2” Class 150 flanged Air connection, 6” nominal Condensate drain connection, 1 ¼ O.D. Return connection, 2” Class 150 flanged Relief valve connection, ¾”...
  • Page 113 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Dimensions (continued) Figure 99 Dimensional data — 1000/1100 LEGEND Supply connection, 3” Class 150 flanged Air connection, 6” nominal Condensate drain connection, 1 ¼ O.D. Return connection, 3” Class 150 flanged Relief valve connection, 1 ¼”...

  • Page 114: Atings - Svf Tm Series 1 Boilers

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Ratings — Series 1 boilers Figure 100 Ratings and engineering data AHRI Certiifed Ratings Boiler Boiler Gross Thermal Combustion Water Vent/Air Stack/vent Boiler weight Model Output Input Rating Efficiency Efficiency Content...

  • Page 115: Installation And Service Certificate

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Installation and Service Certificate Boiler Model Series CP Number Date Installed ❏ BTU Input Installation instructions have been followed. ❏ Check-out sequence has been performed. ❏ Above information is certified to be correct. ❏...
  • Page 116 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Installation and Gas Boiler Data Collection Sheet %RLOHU 0RGHO  6HULHV ________ / 6HULHV _______ 'DWH ,QVWDOOHG: ___________________ &3 1XPEHU: __________________ Fuel Type: ___________ BTU Input: ____________ )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW +,*+ ¿UH BBBBBBBBBBBBBBBBB )ODPH VLJQDO RQ FRQWURO GLVSOD\ DW /2: ¿UH BBBBBBBBBBBB Was venturi changed? YES___ NO___ Was gas valve throttle adjusted? YES___ NO___...

  • Page 117: Installation And Gas Boiler Data Collection Sheet

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Installation and Gas Boiler Data Collection Sheet CO2 @: High Fire______% Low Fire______% CO@: High Fire _____ ppm Low Fire _____ ppm Input rate measured: HIGH ______ CFH / LOW________ CFH 3ULRULW\  6HWWLQJV 3ULRULW\  6HWWLQJV 3ULRULW\  6HWWLQJV...

  • Page 118: Notes

    — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Notes Part number 550-100-200/1018...
  • Page 119 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER Notes (continued) Part number 550-100-200/1018...
  • Page 120 — Boiler Manual ™ Series 1 COMMERCIAL CONDENSING GAS FIRED WATER BOILER...

This manual is also suitable for:

Svf 750Svf 1100Svf 1000

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