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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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Table of Contents
Related Manuals for Weil-McLain SVF 750
Summarization of Contents
Please Read Before Proceeding
Installer and User Instructions
Instructions for installers and users regarding boiler installation and service.
Boiler Servicing and Operation Precautions
Safety guidelines for servicing and operating the boiler, including warnings.
Prepare Boiler Location
Installation Compliance and Site Requirements
Requirements for boiler installation location, including flooring and foundation.
Garage Installation Precautions
Specific safety precautions for installing the boiler in a garage environment.
Prepare Boiler Location (Continued)
Boiler Clearances and Air Openings
Specifies minimum clearances for combustible surfaces and service access.
Prepare Boiler Location (Continued)
Multiple Boiler Placement Guidelines
Guidelines for side-to-side mounting and clearances for multiple boiler installations.
Prepare Boiler
Combustion Air Provision and Sizing for Direct Exhaust
Details on providing and sizing air openings for boiler room and appliance needs.
Vent and Air Piping Requirements
Information on specific vent system requirements and piping configurations.
Prepare Boiler (Continued)
Boiler Uncrating and Handling
Procedures for safely uncrating and moving the boiler, including warnings.
Prepare Boiler (Continued)
Boiler Placement and Leveling
Steps for placing the boiler and adjusting leveling legs for proper positioning.
Bolting Boiler to Mounting Blocks
Instructions for securing the boiler to mounting blocks, especially for seismic zones.
Prepare Boiler (Continued)
Propane Conversion Procedure
Step-by-step guide for converting the boiler from natural gas to propane.
Boiler Relief Valve and P/T Gauge
Information on installing and selecting appropriate relief valves and P/T gauges.
Prepare Boiler (Continued)
Hydrostatic Pressure Test Procedure
Steps for conducting the hydrostatic pressure test on the boiler system.
Boiler Drain Valve Installation
Instructions for installing the boiler drain valve for system maintenance.
Install Water Piping
General Piping Information and Controls
Guidelines for general piping, additional controls, and system types.
Low Water Cutoff and P/T Gauge Installation
Details on installing low water cutoff and pressure/temperature gauges.
Install Water Piping (Continued)
Recommended Pipe Sizing and Flow Rates
Guidance on selecting appropriate pipe sizes and understanding flow rate data.
Install Water Piping (Continued)
Expansion Tank Types and Installation
Information on diaphragm and closed-type expansion tanks and their piping.
Install Water Piping (Continued)
Zone Valve Zoning Configuration
How to configure zone valve systems with primary/secondary piping.
DHW Tank Integration and System Priorities
Connecting DHW tanks and setting system priorities for heating and DHW.
Install Water Piping (Continued)
High-Flow DHW Circuit Zoning
Zoning for high-flow-rate or high-head-loss DHW circuits using zone valves.
Install Water Piping (Continued)
Circulator Zoning with Primary/Secondary Piping
Configuring circulator zoning using primary/secondary piping methods.
Install Water Piping (Continued)
Radiant Heating System Zoning
Using zone valves for radiant heating systems with primary/secondary piping.
Install Water Piping (Continued)
Chilled Water Systems with Zone Valves
Piping configurations for chilled water systems using zone valves and primary/secondary loops.
Venting/Air Piping — Massachusetts Installations
Massachusetts Venting Requirements
Specific installation requirements for sidewall horizontally-vented gas equipment in Massachusetts.
Venting/Combustion Air — General
Combustion Air Provision Methods
Explains direct exhaust and direct vent methods for combustion air supply.
Vent and Air Piping Material Requirements
Lists approved materials for vent and air piping systems.
Venting/Combustion Air — General (Continued)
Combustion Air Contamination Sources
Identifies products and areas that can contaminate combustion air.
Venting/Combustion Air — Options (Category II & IV)
Approved Vent and Air Piping Materials
Lists specific materials approved for Category II and IV venting and air piping.
Appliances Remaining on Existing Vent System
Common Venting Prohibitions and Testing
Explains why common venting is prohibited and outlines vent system verification tests.
Venting/Combustion Air — Options (Category II)
Category II Venting Requirements
Details specific requirements for Category II venting systems, including negative pressure.
Venting/Combustion Air — Options (Category II) (Continued)
Code Compliance for Category II Venting
Refers to codes and standards for venting/combustion air piping installations.
Venting/Combustion Air — Options (Category IV)
Boiler Vent and Air Connections and Piping Limits
Lists acceptable vent/air pipe terminations and maximum length limits for Category IV.
Direct Exhaust — Boiler Room Air Openings (Category II and IV)
Combustion Air Provision and Sizing for Direct Exhaust
Guidelines for providing and sizing boiler room air openings for direct exhaust installations.
Special Considerations for Tight Construction and Air Movers
Factors like tight construction and exhaust fans affecting air opening requirements.
Direct Exhaust — Boiler Room Air Openings (Continued) (Category II and IV)
Minimum Combustion Air Opening Sizes
Charts detailing minimum free area for direct exhaust air openings based on appliance load.
Direct Exhaust — Vertical (Category II and IV)
Vertical Direct Exhaust Termination Location
Instructions for determining the correct termination location for vertical direct exhaust.
Vent Piping Installation and Termination
Procedures for installing vent piping and termination for vertical direct exhaust systems.
Direct Exhaust — Sidewall Termination Location (Category IV)
Sidewall Termination Location Requirements
Specifies clearances and placement requirements for sidewall direct exhaust terminations.
Direct Exhaust — Sidewall (Category IV)
Sidewall Termination Location and Piping Installation
Procedures for determining sidewall termination location and installing vent piping.
Direct Exhaust — Sidewall (Continued) (Category IV)
Multiple Sidewall Terminations and Assembly
Details for multiple boiler sidewall terminations and termination assembly instructions.
Direct Vent — Boiler Room Air Openings (Category IV)
Combustion Air Provision and Sizing for Direct Vent
Guidelines for direct vent combustion air provision and sizing of boiler room openings.
Manifolded Combustion Air Option
Instructions for using a common combustion air manifold for multiple boilers.
Direct Vent — Boiler Room Air Openings (Continued) (Category IV)
Minimum Combustion Air Openings for Direct Vent
Charts detailing minimum free area for direct vent air openings based on appliance load.
Direct Vent — Sidewall Termination Location (Category IV)
Sidewall Termination Location Requirements for Direct Vent
Specifies clearances and placement requirements for sidewall direct vent terminations.
Direct Vent — Sidewall (Category IV)
Sidewall Termination Location and Vent Piping Installation
Procedures for determining sidewall termination location and installing vent piping.
Direct Vent — Sidewall (Continued) (Category IV)
Multiple Sidewall Terminations and Assembly
Details for multiple boiler sidewall terminations and termination assembly instructions.
Direct Vent — Vertical (Category IV)
Vertical Direct Vent Termination Location
Instructions for determining the correct termination location for vertical direct vent.
Vertical Vent and Air Piping Installation
Procedures for installing vent and air piping for vertical direct vent systems.
Direct Vent — Vertical (Continued) (Category IV)
Vertical Vent and Air Terminations
Details on installing vertical vent and air terminations, including multiple boilers.
Direct Vent — Vertical (Continued) (Category IV)
Vertical Vent and Sidewall Air Termination Assembly
Assembly instructions for vertical vent with sidewall air termination configurations.
Install Condensate Components
Condensate Trap Installation and Connection
Procedures for installing the condensate trap and connecting the condensate line.
Gas Piping
Connecting Gas Supply Piping
Steps for connecting the gas supply piping to the boiler, including safety warnings.
Gas Supply Pressure Checks
How to check natural or LP gas supply pressure and connections.
Gas Piping (Continued)
Gas Pipe Sizing and Pressure Switches
Guidance on sizing gas pipes for natural gas and propane, and details on pressure switches.
Field Wiring
Wiring Entrances and Overview
Information on knockouts for wiring and a general wiring overview.
Line Voltage Power Input Requirements
Requirements for connecting the main 120VAC power supply to the boiler.
Field Wiring Schematic Diagram (Continued)
SVF Boiler Schematic Wiring Diagram
Visual representation of the SVF boiler's schematic wiring connections.
Field Wiring Schematic Diagram (Continued)
SVF Boiler Schematic Wiring Diagram Details
Further details and continuation of the SVF boiler's schematic wiring diagram.
Field Wiring Ladder Diagram (Continued)
SVF Boiler Ladder Wiring Diagram
Visual representation of the SVF boiler's ladder wiring diagram.
Field Wiring Ladder Diagram (Continued)
SVF Commercial Boiler Series 1 Ladder Wiring Diagram
Detailed ladder wiring diagram for the SVF Commercial Boiler Series 1.
Field Wiring (Continued)
120 VAC Power Supply Requirements
Essential requirements for connecting the 120 VAC power supply to the boiler.
120 VAC Outputs for System Components
How 120 VAC outputs are used for system components like circulators.
Field Wiring (Continued)
120 VAC Boiler Circulator Connection
Required connection for the 120 VAC boiler circulator.
24 VAC Inputs for System Devices
Using 24 VAC inputs for system devices like thermostats and end switches.
Field Wiring (Continued)
System Supply and Return Temperature Sensors
Requirements for installing system supply and return temperature sensors.
Optional Outdoor Temperature Sensor
Information on installing and using an optional outdoor temperature sensor.
Field Wiring (Continued)
Optional External Limits for Manual/Automatic Reset
Connecting external limits for manual or automatic reset functions.
Optional Alarm Contacts
Wiring alarm contacts for remote notification.
Field Wiring (Continued)
Closure Switch Interlocks (Flow Switch/CAD)
Configuring closure switches for flow switches or combustion air dampers.
Field Wiring (Continued)
0-10 VDC Remote Target Input Configuration
Setting up a 0-10 VDC input for remote target temperature adjustment.
Field Wiring (Continued)
0-10 VDC Remote Modulation Input
Using a 0-10 VDC input for remote modulation of boiler operation.
Field Wiring (Continued)
Multiple Boiler and BMS Connections
Connecting multiple boilers and building management systems.
Additional Heat Demand Contacts
Connecting optional contacts for additional heat demand signals.
0-10 VDC Output Section
Using the 0-10 VDC output for controlling external heat sources.
Zoning with the SVFTM Control
Circulator Zoning Applications
Suggested applications for zoning with circulators for heating and DHW.
Zoning with the SVFTM Control (Continued)
Zone Valve Zoning Applications
Suggested applications for zoning with zone valves and controllers.
Control Operation and Setup
Control Features Overview
Summary of the control's features and capabilities for boiler operation.
Boiler Control Sequence of Operation
Explains the sequence of operations for the boiler control system.
Control Operation and Setup (Continued)
Control Priorities and Input/Output Configuration
How to configure priorities and assign inputs/outputs for system control.
Boiler Setup Wizard and Manual Configuration
Steps for setting up the boiler using the Wizard or manual control menus.
Control Operation and Setup (Continued)
Outdoor Reset Operation Settings
Configuring outdoor reset settings for supply temperature adjustment.
Control Operation and Setup (Continued)
Single Boiler Essential Settings
Essential settings required for single boiler startup and configuration.
Control Operation and Setup (Continued)
SVF Control Display Screens and Navigation
Overview of the SVF control display screens and how to navigate them.
Control Operation and Setup (Continued)
Control Settings in BASIC MODE
Available control settings in BASIC MODE, including system types.
Contractor Menus
Boiler Settings Menu Options
Accessing and configuring boiler settings via the contractor menu.
Priority Settings Configuration
Setting up priority levels for different system operations.
Assign Inputs Menu
Assigning inputs to specific system priorities and functions.
Diagnostics and Maintenance Information
Accessing diagnostic data and setting maintenance reminders.
Boiler Settings Menu, BASIC Mode
Boiler Model and Altitude Configuration
Crucial settings for boiler model, altitude, and fuel type.
Control Type and High Altitude Settings
Selecting control type (single/master/shadow) and configuring high altitude settings.
Priority 1, 2, 3 Menus, BASIC Mode
Priority System Type and Target Sensor Configuration
Setting system types and target sensors for each priority level.
Assign Inputs Menu, BASIC Mode
Input Assignment for Priority and Aux Functions
Assigning system priorities and AUX PUMP/OUTPUT functions to inputs.
Assign Inputs Menu, BASIC Mode (Continued)
AUX PUMP/OUTPUT Operation Modes
Explains different modes for AUX PUMP/OUTPUT operation based on boiler status.
Diagnostic Menu
Diagnostic Menu Navigation and Information
How to navigate the diagnostic menu and view system information.
Diagnostics Menu (Continued)
Network Inputs and Software Versions
Viewing network input status and software versions.
Past Errors and Lockout History
Accessing past error logs and lockout histories for troubleshooting.
Diagnostics Menu (Continued)
Diagnostic Menu Details - Temperatures and Inputs
Detailed information on temperature sensors and input statuses within diagnostics.
Diagnostic Menu Details - Outputs and Runtime
Information on boiler outputs, circulator status, and runtime data.
Diagnostics Menu (Continued)
Master-Shadow and Network Boiler Diagnostics
Diagnostic information for master-shadow configurations and network boilers.
Resetting History Counters
Procedure for resetting diagnostic history counters to zero.
Diagnostics Menu (Continued)
Lockout History Details and Manual Test Mode
Viewing detailed lockout histories and using manual test mode for diagnostics.
Maintenance, Date and Time Menus
Setting Contractor and Maintenance Information
Entering contractor details and setting maintenance reminders.
Setting System Date and Time
Configuring the system date and time for accurate logging.
Startup — Fill the System
Cleaning System for Sediment Removal
Procedures for flushing the system to remove sediment before filling.
Water Chemistry and Antifreeze Requirements
Guidelines for maintaining proper water pH, hardness, and antifreeze levels.
Startup — Fill the System (Continued)
Freeze Protection and System Purging
Guidelines for freeze protection fluids and purging air from the water system.
Checking Inhibitor and Antifreeze Concentrations
Annual checks for inhibitor and antifreeze concentrations in the system.
Startup — Final Checks
Thermostat Circuit and Condensate System Checks
Verifying thermostat circuits and inspecting the condensate system.
Pressure Switch Hoses and Pre-Startup Checklist
Inspecting pressure switch hoses and reviewing pre-startup checklist items.
Startup Procedure
Initial Boiler Startup and Operation Checks
Steps for starting the boiler and checking its initial operation.
Flame and Combustion Adjustment
Procedures for checking and adjusting flame and combustion parameters.
Startup Procedure (Continued)
Gas Valve Adjustment and Control Testing
Adjusting the gas valve and testing boiler controls for proper function.
Startup Procedure (Continued)
Gas Input Rate Measurement and Leak Testing
Measuring gas input rate and performing gas valve leakage tests.
Startup Verification Checklist
A comprehensive checklist to verify all startup procedures have been completed.
Startup Procedure (Continued)
Boiler Operating Instructions and Gas Shutoff
Key operating instructions, including safety warnings and gas shutoff procedures.
Annual Startup and Maintenance Schedule
Service Technician Responsibilities
Tasks for service technicians during annual startup and maintenance.
Owner Maintenance Tasks
Routine maintenance tasks for the boiler owner.
Annual Startup (Continued)
Handling Ceramic Fiber Materials
Safety precautions for handling ceramic fiber materials used in the boiler.
First-Year Special Inspection Requirements
Specific inspection items required within the first year of boiler installation.
Annual Startup (Continued)
Checking for Leaks and Air Openings
Procedures for checking water, gas, and air systems for leaks and obstructions.
Water System and Boiler Relief Valve Checks
Verifying water system pressure and checking the boiler relief valve.
Annual Startup (Continued)
Expansion Tank Inspection and Function
Inspecting expansion tanks for proper size, charge, and function.
Ignition Electrode and Wiring Checks
Inspecting and testing the ignition electrode, flame sense rod, and wiring.
Annual Startup (Continued)
Boiler Wiring and Control Setting Checks
Verifying all boiler wiring connections and control settings.
Burner Flame Inspection and Access
Procedures for inspecting the burner flame and accessing the burner for maintenance.
Annual Startup (Continued)
Burner and Cover Plate Re-installation
Steps for correctly re-installing the burner and cover plate assembly.
Annual Startup (Continued)
Flame Signal and Flue Gas Temperature Checks
Checking flame signal quality and flue gas temperature for proper operation.
Blower Speed Checks and Manual Test Mode
Verifying blower speeds and using manual test mode for diagnostics.
Troubleshooting
Before Troubleshooting and Recommended Tools
Essential preliminary steps and tools needed for troubleshooting boiler issues.
Troubleshooting (Continued)
Checking Control Module Fuses
Procedures for checking and replacing fuses for the control module.
Checking Temperature Sensors
Method for testing temperature sensor resistance values at various temperatures.
Troubleshooting (Continued)
Control Fault Indications and Reset Procedures
Understanding control fault displays and procedures for resetting lockouts.
Troubleshooting (Continued)
Control Error Condition Log and Lockout History
How to access and interpret the control's error log and lockout histories.
Troubleshooting (Continued)
Boiler Not Responding to Call for Heat Troubleshooting
Diagnosing and correcting issues when the boiler does not respond to a call for heat.
Troubleshooting (Continued)
Low Water Cutoff and Temperature Sensor Faults
Troubleshooting low water cutoff faults and temperature sensor errors.
Troubleshooting (Continued)
Limit Open and High Temperature Limit Faults
Diagnosing and resolving issues related to limit switches and high temperature limits.
Troubleshooting (Continued)
Ignition Faults and Air Pressure Switch Issues
Troubleshooting ignition faults and air pressure switch problems.
Troubleshooting (Continued)
Minimum Air Flow, Hardware, and Flue Temp Faults
Addressing minimum air flow, hardware, and flue temperature faults.
Maintenance
Disconnecting Power and Startup Checks
Safety procedures for disconnecting power and verifying operation after maintenance.
Cleaning Heat Exchanger (Water and Flue Sides)
Step-by-step instructions for cleaning the heat exchanger from both water and flue sides.
Maintenance (Continued)
Removing and Re-installing Burner and Cover Plate
Procedures for removing and reinstalling the burner and heat exchanger cover plate.
Maintenance (Continued)
Cover Plate Nut Tightening Sequences
Specific sequence and torque for tightening cover plate nuts.
Replacement Parts
Miscellaneous Parts and Kits Identification
Listing of various replacement parts and kits with their part numbers.
Replacement Parts (Continued)
Jacket Parts Identification
Identification and part numbers for various jacket components.
Replacement Parts (Continued)
Jacket Parts Illustration
Visual diagram of jacket parts with corresponding item numbers.
Replacement Parts (Continued)
Burner, Blower, Venturi, Gas Train Parts
Listing of part numbers for burner, blower, venturi, and gas train components.
Replacement Parts (Continued)
Burner, Blower, and Gas Train Assembly Diagram
Illustration of burner, blower, venturi, gas train, and miscellaneous parts.
Replacement Parts (Continued)
Controls and Harness Part Numbers
Part numbers for various controls, displays, and wiring harnesses.
Replacement Parts (Continued)
Controls Illustration
Visual diagram of various control components with corresponding item numbers.
Dimensions
SVF 750 Dimensional Data
Table and diagram showing dimensional data for the SVF 750 model.
Dimensions (Continued)
SVF 1000/1100 Dimensional Data
Table and diagram showing dimensional data for SVF 1000/1100 models.
Ratings — SVFTM Series 1 Boilers
AHRI Certified Ratings and Engineering Data
Table detailing boiler ratings, efficiencies, and weights.
Vent/Air Piping Length Derate Calculations
Formulas and examples for calculating derates based on vent/air piping length.
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