Weil-McLain SVF 1500 Manual
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Weil-McLain SVF 1500 Manual

Commercial condensing gas-fired water boilers
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Series 1
Models 1500 - 3000
Commercial Condensing
as- red a er oilers
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
unless combustion air is piped to the boiler air inlet from a dust-free and contaminant-
free area. Th e boiler can be severely damaged by drywall dust or other combustion air contaminants.
Part number 550-100-250/0819

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  • Page 1 Series 1 Models 1500 - 3000 Commercial Condensing as- red a er oilers 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.
  • Page 2 Commercial Condensing Water Boiler Heat exchanger stainless steel vertical tube. The control can operate a single boiler or coordinate with other SVF 1500-3000 Series 1 boilers in a multiple boiler system. Control inputs and outputs allow operation of multiple heating circuits Blower ( 1500 shown) (space heating and DHW, for example).
  • Page 3 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Commercial Condensing Water Boiler Electrical panel components Components - Top View Components - Back View Components - Front View Part number 550-100-250/0819...

  • Page 4: Table Of Contents

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Contents Contents ......4 Hazard definitions .
  • Page 5 See the instructions at right. contact with water, replace the boiler with a new Weil-McLain boiler. damage. When servicing boiler —...
  • Page 6 CSA C22.1, Part 1, Canadian Electrical Code, and/or local codes. Boiler model For Canada only: CAN/CSA B149.1, Natural Gas and Propane Installation Code, and any local codes. SVF 1500 38 x 67 Where required by the authority having jurisdiction, the installation 38 x 67...
  • Page 7 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Prepare boiler location (continued) Openings in fl oors, walls, ceilings or roofs must be Cl earan ce requirements designed for fi re stopping as required by local codes. Clearances from combustible materials Vent pipe openings through combustible materials must be 3/8”...
  • Page 8 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual 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 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Prepare boiler Provide air openings to room Air openings — General — 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 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual 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 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Prepare boiler (continued) Placing the boiler Figure 5 Seimic mounting brackets (provided by others) 1. Roll the boiler down the ramp and move the boiler into position. 2. Th e piping end casters are swivel type. Th e piping and front end casters are swivel, middle casters are fi xed.
  • Page 12 BEFORE boiler in the envelope assembly. any isolation valve. 2. Verify that the stamping on the orifi ce disk is correct for model size: One orifi ce for SVF 1500/2000/2500/3000 Perform hydrostatic pressure test Orifi ce size = 0.660".
  • Page 13 8. Apply pipe dope to the P/T gauge and install in the ¼-inch tap- ping as shown. 9. Install plug on the relief valve nipple, SVF 1500/2000 – 1 ¼” FNPT and SVF 2500/3000 – 2” FNPT. 10. If pressure test will be conducted with a pressure over 160 psig the automatic air vent must be removed and a 1/2”...
  • Page 14 1. Install relief valve (shipped loose with the boiler) in the piping from turning. Failure to support the boiler piping (SVF 1500/2000) 1¼ inch or (SVF 2500/3000) 2-inch cou- connections to prevent them from turning could cause pling on top of the boiler supply outlet pipe.
  • Page 15 Figure 17, page 20), a differential pressure by-pass valve should be added to by-pass the excessive flow, or provide an alternate engineered solution. SVF 1500/2000 Lower flow rates: Use Primary/Secondary piping (see pages 17, 18, 21, 22 & 23). In a Variable/Primary flow system (see Figures  16, page  19 Flow Rate (GPM) and Figure ...
  • Page 16 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Install water piping (continued) Recommended pipe sizing (continued) The expansion tank needs to be pre-charged to the required system fill pressure before being Temperature rises shown apply to water only. For glycol/ connected to the system.
  • 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 For DHW applications, assign DHW inputs to determined Priority (1, 2, or 3). Priority 1 is defaulted to DHW for DHW Prior- ity applications. 3. For more than 3 zones, use Weil-McLain WMZV zone valve controller. Legend — Figure 16 13 Zone valves, typical...
  • Page 20 1. Th e control can control up to four circulators (boiler circulator and three 3. For more than 3 zones, use Weil-McLain WMZV zone valve con- others). Refer to Field wiring, beginning on page 59 , for instructions on troller.
  • Page 21 DHW Priority applications. and three others). Refer to Field wiring, beginning on page 59 , for instructions on wiring to circulators. Th e boiler circulator cannot 3. For more than 3-zones, use Weil-McLain WMCR zone Circ. be used for a zone pump. controller.
  • Page 22 Priorities 1 and/or 2 for space heating; Priority 3 for DHW. Th e 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 23 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 111 for details. Chilled medium, if used, is piped in parallel with heating boiler as shown in Figure 20 .
  • Page 24 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual 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 wall horizontally vented gas fueled equipment shall not ap- in every dwelling, building or structure used in whole or in part prove the installation unless, upon inspection, the inspector...

  • Page 25: Venting/Combustion Air - General

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Venting/combustion air — general There are two venting methods available. Follow the instructions on the (no air piping connected to air intake) outside following pages for the method used. Vent and air piping materials Use only the materials listed in this manual ing piping and methods described in this...
  • Page 26 Venting/combustion air — options Boiler vent and air connections: The SVF boiler vent/air connection is sized for the following vent sizes / materials: 1. SVF 1500/2000 8” Duravent-FasNSeal 2. SVF 2500/3000 10” Duravent-FasNSeal Installer must provide the correct adapters/reducers needed to connect to other approved vent manufacturer’s products.
  • Page 27 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Venting/combustion air — options Figure 22 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet local codes Canada Duravent / M&G – PolyPro Certified for Category II &...
  • Page 28 Vent connection is sized for DuraVent- FasNSeal AL29-4C venting. Installers must provide the correct PVC/CPVC adapters. SVF 1500/2000 8” Duravent-FasNSeal SVF 2500/3000 10” Duravent-FasNSeal PVC can only be used on the exhaust of a boiler aft er 10 linear feet of CPVC pipe.
  • Page 29 Stack / Vent maintained at required for Input Vent Connection of the boiler Category II Boiler Btuh scfm Model (See Note 1) SVF 1500 1,500,000 -0.001 to -0.100 8” SVF 2000 1,999,000 -0.001 to -0.100 8” SVF 2500 2,499,000 -0.001 to -0.100 10”...
  • Page 30 In applications where the venting system cannot maintain the required negative pressure on the boiler outlet via natural draft, 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 efficiency of the boiler.
  • Page 31 Boiler vent and air connections: The SVF boiler vent/air connection is sized for the following vent sizes/ materials: SVF 1500/2000 8” Duravent-FasNSeal SVF 2500/3000 10” Duravent-FasNSeal Installer must provide the correct adapters/reducers needed to connect to other approved vent manufacturer’s products.
  • Page 32 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT EXHAUST — Boiler room air openings Special considerations Combustion air provision The SVF Commercial boiler can use inside air if no contaminants are Tight construction present in the boiler space. (If contaminants are likely to be present, National Fuel Gas Code - ANSI Z223.1/NFPA 54 –...
  • Page 33 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT EXHAUST — Boiler room air openings (continued) Figure 26 MINIMUM combustion air openings for direct exhaust applications — Air openings boiler boiler The required air opening sizes below are FREE AREA, WITH other WITHOUT other after reduction for louver obstruction.
  • Page 34 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT EXHAUST — Vertical Figure 27 Vertical direct exhaust termination listed in Figure 22, page 27 Read and follow all instructions in this manual. page 25 through page 35. Locate the termination such that the total vent piping from the boiler to the termi- nation...
  • Page 35 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT EXHAUST — Sidewall Termination location Figure 28 — 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 36 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT EXHAUST — Sidewall Figure 29 Sidewall direct exhaust termination listed in Figure 22, page 27 Read and follow all instructions in this manual. page 25 through page 35. Locate the termination such that the total vent piping from the boiler to the termi- nation...
  • Page 37 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT EXHAUST — Sidewall (continued) 2. Vent pipe penetration: Figure 30 Multiple boiler direct exhaust sidewall a. Cut a hole for the vent pipe. terminations (see Figure 29, page 36 for b.
  • Page 38 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Boiler room air openings Combustion/ventilation air provision Exhaust fans and air movers For direct vent installations, combustion air must be ducted Th e appliance space must never be under a negative pressure unless all ap- directly from outside to the boiler air intake fi tt ing.
  • Page 39 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Boiler room air openings (continued) Figure 33 MINIMUM combustion air openings for direct vent applications — Air openings boiler boiler The required air opening sizes below are FREE AREA, WITH other WITHOUT other after reduction for louver obstruction.
  • Page 40 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Sidewall Termination location Figure 34 — 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 41 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Sidewall Figure 35 Sidewall direct vent terminations — vent and air listed in Figure 22, page 27 Read and follow all instructions in this manual. page 25 through page 35 and page 38 through page 40.
  • Page 42 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Sidewall (continued) 3. Vent pipe penetration: Figure 36 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 43 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Vertical Figure 38 Vertical direct vent terminations (air termination can be vertical or sidewall as shown below). listed in Figure 22, page 27 Read and follow all instructions in this manual. page 25 through page 35 and page 38 through page 40.
  • Page 44 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Vertical (continued) Install vent and air terminations Figure 39 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 45 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIRECT VENT — Vertical (continued) Figure 41 Termination location — multiple boilers — vertical vent/sidewall air. — Space vents minimum 6 inches apart. Space air terminations minimum 6 inches apart.
  • Page 46 Condensate from the boiler will be slightly acidic (typi- cally with a pH from 3.2 to 4.5). Install a neutralizing fi lter if required by local codes. See Replacement parts section at the end of this manual for a Weil-McLain condensate neutralizer kit. Figure 43...

  • Page 47: Gas Piping

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Gas piping piping at boiler , using one wrench to prevent the Connecting gas supply piping boiler gas line connection from turning. Failure to 1. Connect gas supply piping to the boiler, see Figure 46 . support the boiler gas connection pipe to prevent a.

  • Page 48: Gas Train Diagram

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Gas piping (continued) Pipe sizing for Natural Gas Figure 48 Pipe capacity for natural gas 1. Size gas supply piping from meter outlet to entrance of boiler in ac- cordance with Figure 48 and Figure 49.

  • Page 49: Field Wiring (See Figure 51 - Figure 58)

    120VAC power to boiler; 120VAC power out to boiler circulator; system supply and return temperature sensors. 12 Knock-outs Boiler load: SVF 1500/2000 — 23.17 Amps 2500/3000 Three phase 208VAC -3 phase Wye - transformer with neutral and ground for power to blower; 120VAC power out to boiler circulator;...
  • Page 50 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring Figure 51 Single Phase Schematic wiring diagram — boilers (continued on next page) Color version of Wiring Schematic available on Weil-McLain Web site Part number 550-100-250/0819...
  • Page 51 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (continued) Figure 52 Single Phase Schematic wiring diagram — boilers (continued on previous page) Part number 550-100-250/0819...
  • Page 52 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (continued) Figure 53 Single Phase Ladder wiring diagram — boilers (continued on next page) Part number 550-100-250/0819...
  • Page 53 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (continued) Figure 54 Single Phase Ladder wiring diagram — boilers (continued on previous page) Part number 550-100-250/0819...
  • Page 54 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring Figure 55 Three Phase Schematic wiring diagram — boilers (continued on next page) Color version of Wiring Schematic available on Weil-McLain Web site Part number 550-100-250/0819...
  • Page 55 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (continued) Figure 56 Three Phase Schematic wiring diagram — boilers (continued on previous page) Part number 550-100-250/0819...
  • Page 56 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (continued) Figure 57 Three Phase Ladder wiring diagram — boilers (continued on next page) Part number 550-100-250/0819...
  • Page 57 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (continued) Figure 58 Three Phase Ladder wiring diagram — boilers (continued on previous page) Part number 550-100-250/0819...
  • Page 58 1. Boiler line voltage power — Boiler loads are listed below. Provide and install a fused Single Phase disconnect or service switch as required by applicable codes. 120VAC 2. SVF 1500/2000 Connect properly sized power wiring to SVF boiler line voltage terminal strip as shown at right.
  • Page 59 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 51, page 50 for details.
  • Page 60 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (see Figure 28 - Figure 58) (continued) – REQUIRED 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. See SVF boiler manual replacement parts section for available replacement immersion sensors or strap on sensors.
  • Page 61 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (see Figure 51 - Figure 58) (continued) G. External limits – OPTIONAL To cause MANUAL control will require manual reset after circuit is interrupted 1. Remove factory-installed jumper and connect isolated contacts of external limits across P13 pins 1 and 2 to cause the control to enter manual reset lockout if the limit circuit opens.
  • Page 62 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (see Figure 51 - Figure 58) (continued) I. Closure switch (flow switch and/or CAD) – OPTIONAL 1. A flow switch or combustion air damper (CAD) interlock can be configured by removing jumper.
  • Page 63 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (see Figure 51 - Figure 58) (continued) K. 0 –10 VDC Remote TARGET input – OPTIONAL 1. See illustration at right and Figure 51, page 50 (wiring diagram) for details. 2.
  • Page 64 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (see Figure 51 - Figure 58) (continued) L. 0–10 VDC Remote MODULATION input – OPTIONAL control module, left side) — Remote modula- tion using an external controller only works with each boiler set up as a SINGLE boiler in the ni Control setup.
  • Page 65 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Field wiring (see Figure 51 - Figure 58) (continued) M. Multiple Boiler and BMS Connections – see ADVANCED Manual (Expansion module, right side) 1. The boiler control is capable of multiple boiler communication and control of up to eight (8) boilers in one installation.

  • Page 66: Control

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual 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 59 (24VAC inputs). 2.
  • Page 67 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual 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 59 (24VAC inputs). 2.

  • Page 68: Control Operation And Setup

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Control operation and setup Figure 59 Control sequence of operation Control setup 1. Set control parameters using the WIZARD option provided on initial Display Control action start-up or manually enter parameters using control menus (see Fig- status ure 66, page 74 and following pages for information.) (Also see Figure 63, page 72)
  • Page 69 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Control operation and setup (continued) Control Priorities & Input/Outputs Setting Up the Boiler For heating installations with multiple systems, the Control uses PRIORITIES to determine the order of operation of the systems. The control’s MAX and MIN time settings determine the maximum Step 1 and minimum times a system will be operated before being turned...
  • Page 70 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Control operation and setup (continued) Outdoor reset operation Figure 60 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 60.
  • Page 71 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Control operation and setup (continued) Figure 62 SVF single boiler essential settings ( on initial start-up) — see page 73 for explanation Part number 550-100-250/0819...
  • Page 72 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Control operation and setup Control operation and setup (continued) (continued) Figure 63 control display screens and typical navigation Part number 550-100-250/0819...
  • Page 73 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Control operation and setup (continued) Figure 64 control settings available in BASIC MODE (see Advanced Manual for ADVANCED MODE settings) Boiler Model Inputs Assigned (non-selectable) Control Type System Type Priority 1, 2 or 3 High Altitude Target Mod Sensor (non-selectable)

  • Page 74: Contractor Menus

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual CONTRACTOR menus 1. Access contractor menus by pressing and holding the UP and cal settings. DOWN arrow keys at the same time for 7 seconds. Failure to set correctly could result in severe personal injury, death or substantial property 2.

  • Page 75: Personal Injury, Death Or Substantial Property

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual BOILER SETTINGS menu, BASIC mode 1. Access contractor menus by pressing and holding the UP and cal settings. DOWN arrow keys at the same time for 7 seconds. Failure to set correctly could result in severe personal injury, death or substantial property 2.

  • Page 76: Personal Injury, Death Or Substantial Property

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual PRIORITY 1, 2, 3 menus, BASIC mode 1. Access contractor menus by pressing and holding the UP and cal settings. DOWN arrow keys at the same time for 7 seconds. Failure to set correctly could result in severe personal injury, death or substantial property 2.

  • Page 77: Personal Injury, Death Or Substantial Property

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual ASSIGN INPUTS menu, BASIC mode 1. Access contractor menus by pressing and holding the UP and cal settings. DOWN arrow keys at the same time for 7 seconds. Failure to set correctly could result in severe personal injury, death or substantial property 2.
  • Page 78 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual ASSIGN INPUTS menu, BASIC mode (continued) Figure 70 AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 69, page 77) Option Hot loop for seasonal boilers that are manually Output is always energized whenever the control is powered.
  • Page 79 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIAGNOSTIC menu Figure 72 menu navigation (see Figure 63, page 72 for access information) Follow information at the bottom of each screen to navigate to next/previous screen or enter/save data DIAGNOSTICS TEMPERATURES STATUS:...
  • Page 80 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIAGNOSTICS menu (continued) Figure 73 menu navigation, continued (see Figure 73, page 80 for access information) 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 81 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIAGNOSTICS menu (continued) Figure 74 menu details (see Figure 63, page 72 for access information) Comment Temperatures Current operating status of the boiler. Prepurge, Ignition, Name of the system Type being satisfied, post purge, Warm Weather Shut down, Trouble Temperature of the first sensing element of the boiler’s heat exchanger outlet sensor Temperature of the second sensing element of the boiler’s heat exchanger outlet sensor...
  • Page 82 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIAGNOSTICS menu (continued) Figure 75 menu details (continued) (see Figure 63, page 72 for access information) Comment Run Times 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 83 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual DIAGNOSTICS menu (continued) Figure 76 menu details (continued) (see Figure 63, page 72 for access information) Comment Displays time that lockout occurred Displays date that lockout occurred 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 Choose this to view the status of the Boiler Inputs at the time of the error Choose this to view the status of the Boiler Outputs at the time of the error...
  • Page 84 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual MAINTENANCE, DATE AND TIME menus Figure 77 menus — navigation (see Figure 63, page 72 for access information) Comment Contractor name to appear in maintenance reminders and during lockouts Contractor phone number Displays the boiler model selected in the boiler setup Enter the CP# of the boiler...

  • Page 85: Damage

    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 86: Personal Injury, Death Or Substantial Property

    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 87: Personal Injury, Death Or Substantial Property

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Startup — fi nal checks Check thermostat circuit(s) Figure 78 Pressure switch tube locations 1. Disconnect the two external wires connected to the boiler thermostat terminals (see instructions beginning on page 59 for terminal locations).

  • Page 88: Personal Injury, Death Or Substantial Property

    For elevations above 10,000 feet, please contact substantial property damage. Weil-McLain Technical Support for details. 1. Th is procedure is only necessary when combustion tests indicate In Canada, Input rates are derated 10% for the need, as explained under "Check fl...

  • Page 89: Personal Injury, Death Or Substantial Property

    Th e number of tries before Lockout is in accordance with ASME CSD-1 – latest edition. SVF 1500/2000/2500 = One (1) retry, SVF 3000 =Failure and Lockout. Th is means that the ignition system safety device Adjust valve at low fi...
  • Page 90 5. While still in the Gas Valve test screen, give the boiler a call for heat. ❏ Filled out the warranty registration card and send to Th e boiler will go through it’s normal Ignition sequence, but will Weil-McLain? only open Gas Valve 1. ❏ Return instructions to envelope and give to owner or placed 6.
  • Page 91 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Startup procedure (continued) Figure 83 Operating instructions (WARNING — Verify that the control is set correctly before proceeding Part number 550-100-250/0819...

  • Page 92: Annual Startup And Maintenance Schedule

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Annual startup and maintenance schedule Figure 84 Service and maintenance schedules Service technician Owner maintenance (see following pages for instructions) (see User’s Information Manual for instructions) General: Investigate reported problems. Check boiler area.

  • Page 93: Annual Startup

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual 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 and burner perform a first-year inspection of the boiler. This must insulation/gasket.
  • Page 94 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Annual startup (continued) Check air openings The boiler should be inspected and started annu- 1. Verify that combustion and ventilation air openings to the boiler ally, at the beginning of the heating season, only room and/or building are open and unobstructed.
  • Page 95 Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating SVF 1500/2000 – Male spade for fl ame sense. the lever, water will discharge and precautions must be taken to SVF 2500/3000 – Female spade for fl ame sense.
  • Page 96 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Annual startup (continued) Check all boiler wiring Figure 87 Observation windows Inspect all boiler wiring, making sure wires are in good condition and securely att ached. Check control settings 1.
  • Page 97 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Annual startup (continued) 11. Clean the burner. Figure 90 Burner access opening in heat exchanger a. Vacuum cleaner method – Vacuum the burner, being careful not to rub or scrape the fi ber mesh. b.
  • Page 98 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Annual startup (continued) Check flame signal Check flue gas temperature The Unity Control has 3 distinct flame signal thresholds that it 1. Set the boiler to high fire. Then adjust the control module display uses to operate the boiler safely and reliably.

  • Page 99: Troubleshooting

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Troubleshooting Before servicing and making connections . . . — The boiler ON/OFF switch does not turn off all power to the boiler. . Internal wiring is still powered when the switch is off . Label all wires prior to disconnection when servic- Before calling, always complete the “Gas Data Col- ing controls.
  • Page 100 Figure 98 SVF 1500/2000 Circulator and blower fuse location 6. Gas pressure must be as specified on page 47. Make sure gas pressure switches are not tripped. Always check Control module fuses...
  • Page 101 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Troubleshooting (continued) Make sure to determine the causes of outages. Do not leave the boiler operating without a complete diagnosis. boiling point, insert the sensor in water at that temperature. Use Figure 100 Sensor resistance value an ohmmeter to read resistance value.
  • Page 102 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Troubleshooting (continued) Figure 102 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 67, page 75.
  • Page 103 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Troubleshooting (continued) Figure 102 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 104 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Troubleshooting (continued) Figure 102 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 105 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Troubleshooting (continued) Figure 102 Troubleshooting suggestions for boilers (continued) Display Condition Diagnostics Corrective Action(s) Occurs if manual or Automatic external limit will reset Is there an external safety device connected? If yes, trouble shoot the LIMIT OPEN automatic reset limit opens.
  • Page 106 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Troubleshooting (continued) Figure 102 Troubleshooting suggestions for boilers (continued) Display Condition Diagnostics Corrective Action(s) IGNITION Reset by using manual reset Check condensate trap for blockage allowing condensate to accumulate Boiler goes through ( inside heat exchanger.
  • Page 107 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 550-100-250/0819...
  • Page 108 Loosen the hose clamp on the 1” Fernco fitting and the nuts securing the U-bolt to remove the condensate trap assembly. Weil-McLain recommends Sentinel X400 for cleaning b. Place a pan under condensate drain outlet to collect water boiler. See the Replacement Parts section at the end of and any debris.
  • Page 109 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Maintenance (continued) 9. Swing the top rear panel support brackets back into posi- Figure 103 Heat exchanger cover plate gasket and cover plate tion. Secure screws with a 5/16 nut driver. re-installation 10.
  • Page 110 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Maintenance (continued) Figure 104 Cover plate nut tightening sequences Gradually tighten the cover plate and burner plate access bolts in the sequence shown in illustration: Burner & Burner Access Plate torque: 10 N-m/88.5 in-lbs/7.4 ft -lbs. (11mm socket) Cover Plate torque: 20 N-m/177 in-lbs/14.8 ft -lbs.

  • Page 111: Replacement Parts

    Description Part Number Condensate neutralizer kit (up to 3000 MBH) 383-600-287 Pressure relief valve for SVF 1500/2500 ASME 30 PSI, 1¼” NPT female 383-600-093 ASME 50 PSI, 1¼” NPT female 383-600-101 ASME 80 PSI, 1¼” NPT female (includes new P/T gauge) 383-600-299 ASME 100 PSI, 1¼”...
  • Page 112 Kit-Service Jacket Top Center (hardware) SVF 1500 - 3000 384-000-249 Kit-Service Jacket Top Back (hardware) SVF 1500 - 3000 384-000-250 Kit-Service Jacket Back Top - 1 Panel (hardware) SVF 1500 - 3000 384-000-251 Kit-Service Jacket Back Top - 2 Panel (hardware) SVF 1500 - 3000 384-000-252...
  • Page 113 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Replacement parts (continued) Figure 107 Jacket parts Part number 550-100-250/0819...
  • Page 114 384-000-226 Kit-Service Leveling leg kit (Leveling leg, hardware) SVF 1500 - 3000 384-000-227 Kit-Service Condensate trap assembly SVF 1500 - 3000 384-000-228 Kit-Service Inspection glass -Exchanger (Includes glass, retainer, gasket and screws) SVF 1500 - 3000 383-500-020 Part number 550-100-250/0819...
  • Page 115 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Replacement parts (continued) Figure 109 Burner, blower, cover plate, venturi, gas train and miscellaneous Part number 550-100-250/0819...
  • Page 116 Harness-Wiring Control Display (not shown) 591-391-961 Harness-Wiring 48 Inch Control/Display Communication (not shown) 591-392-040 Assembly Igniter/Sensor Cable 435mm Long With Boot SVF 1500-300 (not shown) 591-392-055 Harness-Wiring Control-Tray Auxiliary P15, P16 (not shown) 591-392-056 Harness-Wiring Control-Tray Low Voltage Sensors (not shown)
  • Page 117 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Replacement parts (continued) Figure 111 Controls Part number 550-100-250/0819...

  • Page 118: Dimensions

    ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Dimensions Figure 112 Dimensional data — 1500/2000 LEGEND Supply connection, 3” Class 150 fl anged Air connection, 8” nominal Condensate drain connection, 1" O.D. Return connection, 3” Class 150 fl anged Relief valve connection, 1 ¼"...
  • Page 119 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Dimensions (continued) Figure 113 Dimensional data — 2500/3000 LEGEND Supply connection, 3” Class 150 fl anged Air connection, 10” nominal Condensate drain connection, 1" O.D. Return connection, 3” Class 150 fl anged Relief valve connection, 2”...
  • Page 120 (Note 1) (Note 1) (Note 2) (Note 3) Note 4) Gallons (Note 5) (Note 6) weight (no water) SVF 1500 1,500,000 199,000 300,000 1,448,000 1,259,000 96.5 –– 2020 3000 2445 SVF 2000 1,999,000 199,000 300,000 1,923,000 1,672,000 96.2 –– 2020...
  • Page 121 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Installation and Service Certificate Boiler Model Series Consumer Protection (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 122 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual Installation and Gas Boiler Data Collection Sheet Boiler Model / Series ________ / Series _______ Date Installed: ___________________ CP Number: __________________ Fuel Type: ___________ BTUH Input: ____________ Was venturi changed? YES___ NO___ Was gas valve throttle adjusted? YES___ NO___ Was gas valve offset adjusted? YES___ NO___ Boiler Settings...
  • Page 123 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual 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 Priority 4 Settings Priority 2 Settings Priority 3 Settings...
  • Page 124 ™ Series 1 Commercial Condensing Gas-Fired Water Boiler — Boiler Manual...

This manual is also suitable for:

Svf 3000Svf 2000Svf 1 seriesSvf 2500

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