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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 1100
Summarization of Contents
Please read before proceeding
Commonwealth of Massachusetts
Specific requirements for installations in Massachusetts.
Prepare boiler location
Flooring and foundation
Requirements for the boiler's placement surface and support structure.
Garage installation
Specific precautions to take when installing the boiler in a garage environment.
Prepare boiler location (continued)
Clearance requirements
Specifies minimum distances from combustible materials and for service access.
Air openings
Details requirements for ventilation and combustion air openings.
Prepare boiler
Vent and air piping requirements
Outlines requirements for vent and air piping systems.
Prepare boiler (continued)
Uncrating the boiler
Instructions for safely removing the boiler from its shipping crate.
Moving/handling the boiler
Guidelines for safely transporting and positioning the boiler.
Prepare boiler (continued)
Placing the boiler
Steps for positioning the boiler and adjusting leveling legs.
Bolting the boiler to mounting blocks
Instructions for securing the boiler to the floor if required.
Prepare boiler for propane (when required)
Converting existing natural gas-fired boiler for propane
Procedure to convert the boiler from natural gas to propane.
Boiler relief valve and P/T gauge
Install relief valve
Guidance on installing the pressure relief valve correctly.
Perform hydrostatic pressure test
Pressure test boiler
Procedure for performing a hydrostatic pressure test on the system.
Install water piping
Low water cutoff
Details on the factory-installed low water cutoff.
Install relief valve
Instructions for installing the pressure relief valve.
Install water piping (continued)
Recommended pipe sizing
Guidance on selecting appropriate pipe sizes for optimal flow.
Install water piping (continued)
Expansion tank and make-up water
Information on expansion tank installation and water makeup.
Install water piping (continued)
Domestic Hot Water (DHW) tank, if used
How to connect and configure DHW tanks.
System Priority choices
Explains how to set priorities for DHW and space heating.
Venting/air piping — Massachusetts installations
Venting instructions for the installations in the Commonwealth of Massachusetts
Specific venting requirements for MA installations.
Venting/combustion air — general
Vent and air piping materials
Lists approved materials for vent and air piping systems.
Air openings for direct exhaust
Requirements for air openings for direct exhaust ventilation.
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
Lists approved vent and air piping materials and suppliers.
Appliances remaining on an existing vent system
Existing vent test procedure
Procedure to test existing appliances on a common vent.
Venting/combustion air — options (Category II)
Category II Requirements
Outlines specific requirements for Category II venting.
Venting/combustion air — options (Category IV)
Figure 21 SVF TM boiler venting and air piping — OPTIONS and PIPING LIMITS — The table below lists the acceptable vent/air pipe terminations described in this manual.
Details venting options, piping limits, and derating factors.
DIRECT EXHAUST — Boiler room air openings (Category II and IV)
Sizing combustion air openings
Guidance on determining the correct size for air openings.
Required Combustion Air Damper Kit
Information on the necessity and installation of the damper kit.
DIRECT EXHAUST — Vertical (Category II and IV)
Determine termination location
Steps to identify the correct location for vertical exhaust termination.
Install vent piping
Guidance on installing the vent piping for vertical exhaust.
DIRECT EXHAUST — Sidewall Termination location (Category IV)
Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent buildings, openable windows and building openings shall not be less than those values specified in the National Fuel Gas Code - ANSI Z223.1/ NFPA 54 – latest edition, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.
Specifies minimum clearances and placement requirements for sidewall terminations.
DIRECT EXHAUST — Sidewall (Category IV)
Determine termination location
Steps to identify the correct location for sidewall exhaust termination.
Install vent piping
Guidance on installing the vent piping for sidewall exhaust.
DIRECT VENT — Boiler room air openings (Category IV)
Sizing air openings
Guidance on determining the correct size for air openings for direct vent.
Required Combustion Air Damper Kit
Information on the necessity and installation of the damper kit for direct vent.
DIRECT VENT — Sidewall Termination location (Category IV)
Vent Termination Locations – the minimum distance from adjacent public walkways, adjacent buildings, openable windows and building openings shall not be less than those values specified in the National Fuel Gas Code - ANSI Z223.1/ NFPA 54 – latest edition, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.
Specifies minimum clearances and placement requirements for sidewall terminations.
DIRECT VENT — Sidewall (Category IV)
Determine termination location
Steps to identify the correct location for sidewall direct vent termination.
Install vent piping
Guidance on installing the vent piping for sidewall direct vent.
DIRECT VENT — Vertical (Category IV)
Determine termination location
Steps to identify the correct location for vertical direct vent termination.
Install vent piping
Guidance on installing the vent piping for vertical direct vent.
DIRECT VENT — Vertical (continued) (Category IV)
Install vent and air terminations
Instructions for installing both vent and air terminations.
Install condensate components
Install the condensate trap
Steps for installing the condensate trap assembly.
Connect condensate line
Guidance on connecting the condensate line to a drain or pump.
Gas piping
Connecting gas supply piping
Instructions for connecting the gas supply to the boiler.
Check Natural or LP gas supply pressure
Procedure to check gas pressure for natural or LP gas.
Gas piping (continued)
Pipe sizing for Natural Gas
Guidelines for sizing gas pipes for natural gas installations.
Gas pressure switches
Information on the boiler's gas pressure switches.
Field wiring (see Figure 47 & Figure 48)
Line voltage power input
Information on connecting the main power supply to the boiler.
Required wiring connections
Essential wiring needed for boiler operation.
Field wiring Schematic Diagram (continued)
Figure 47 Schematic wiring diagram — SVF TM boilers (continued on next page)
Wiring diagram details for the boiler control system.
Field wiring Schematic Diagram (continued)
Figure 57 (continued from previous page) Schematic wiring diagram — SVF TM boilers
Continuation of the wiring diagram details.
Field wiring Ladder Diagram (continued)
Figure 48 Ladder wiring diagram — SVF TM boilers (continued on next page)
Ladder diagram details for boiler wiring.
Field wiring (see Figure 47 & Figure 48) (continued)
A. 120 VAC Power Supply – REQUIRED
Details on connecting the main 120VAC power supply.
B. 120 VAC Outputs 1, 2 & 3 – On each boiler – As needed for systems
Information on the boiler's 120VAC outputs for system components.
Field wiring (see Figure 47 & Figure 48) (continued)
C. 120 VAC to Boiler Circulator – REQUIRED
Instructions for wiring the boiler circulator.
D. 24 VAC Inputs 1, 2 and 3 (tstats, end switches, etc.) – As needed for systems
Details on connecting 24VAC inputs for thermostats and other devices.
Field wiring (see Figure 47 & Figure 48) (continued)
E. System supply and return temperature sensors – REQUIRED
Information on installing and wiring temperature sensors.
F. Outdoor temperature sensor – OPTIONAL
Instructions for installing an optional outdoor temperature sensor.
Field wiring (see Figure 47 & Figure 48) (continued)
G. External limits – OPTIONAL
How to connect optional external limit controls.
H. Alarm contacts – OPTIONAL
Connecting optional alarm contacts for remote notification.
Field wiring (see Figure 47 & Figure 48) (continued)
I. Closure switch (flow switch and/or CAD) – OPTIONAL
Connecting optional closure switches like flow switches or CADs.
Field wiring (see Figure 47 & Figure 48) (continued)
K. 0 –10 VDC Remote TARGET input – OPTIONAL
Using a 0-10VDC input for remote target temperature control.
Field wiring (see Figure 47 & Figure 48) (continued)
L. 0–10 VDC Remote MODULATION input – OPTIONAL
Using a 0-10VDC input for remote modulation control.
Field wiring (see Figure 47 & Figure 48) (continued)
M. Multiple Boiler and BMS Connections – see ADVANCED Manual
Information on connecting multiple boilers and BMS systems.
N. Additional heat demand contacts – OPTIONAL
Connecting optional contacts for additional heat demands.
Zoning with the SVFTM Control
A. Zoning with CIRCULATORS, suggested applications
Suggested applications for zoning using circulators.
WMCR circulator zone controller plus DHW controlled by boiler, DHW piped directly to boiler
Specific setup for WMCR controller with DHW.
Zoning with the SVFTM Control (continued)
B. Zoning with ZONE VALVES, suggested applications
Suggested applications for zoning using zone valves.
Control operation and setup
Control features
Overview of the boiler control's capabilities and functions.
Sequence of operation
Description of the boiler's operating sequence and display statuses.
Control operation and setup (continued)
Control Priorities & Input/Outputs
Explains how priorities and inputs/outputs are used for system control.
Setting Up the Boiler
Step-by-step guide for initial boiler setup and configuration.
Control operation and setup (continued)
Outdoor reset operation
How to configure outdoor reset for supply temperature control.
SUPPLY MAX
Setting the maximum supply water temperature for the system.
Control operation and setup (continued)
Figure 52 SVF TM single boiler essential settings (REQUIRED on initial start-up) — see page 67 for explanation
Visual guide to essential settings required during initial boiler startup.
Control operation and setup (continued)
Available settings from CONTRACTOR MENU
Lists settings accessible via the contractor menu.
CONTRACTOR menus
BOILER SETTINGS
Configuration options for boiler model, altitude, fuel, etc.
PRIORITY 1
Settings for system priority 1.
PRIORITY 2
Settings for system priority 2.
BOILER SETTINGS menu, BASIC mode
BOILER MODEL
Crucial setting for correct boiler identification and operation.
CONTROL TYPE
Options for selecting single, master, or shadow boiler configuration.
HIGH ALTITUDE
Setting for altitudes above 5500 feet to adjust firing rates.
PRIORITY 1, 2, 3 menus, BASIC mode
SYSTEM TYPE
Selecting the system type to preset operating temperatures.
TARGET MOD SENSOR
Determining the primary temperature sensor for modulation.
TARGET ADJUST
How the target temperature is calculated (fixed, analog, or outdoor reset).
ASSIGN INPUTS menu, BASIC mode (continued)
Figure 60 AUX PUMP/OUTPUT operation (accessed in ASSIGN INPUTS menu – see Figure 59, page 71)
Explains the operation of AUX PUMP/OUTPUT based on boiler status.
DIAGNOSTIC menu
TEMPERATURES
Displays current temperature readings from various sensors.
INPUTS
Shows the status and configuration of system inputs.
OUTPUTS
Displays the status of boiler outputs and auxiliary functions.
DIAGNOSTICS menu (continued)
PAST ERRORS
Accesses historical fault and lockout information.
MANUAL TEST MODE
Allows manual control of boiler functions for testing.
DIAGNOSTICS menu (continued)
Inputs
Detailed explanation of each input's function and status.
DIAGNOSTICS menu (continued)
Run Times
Tracks cumulative operating times for various boiler functions.
DIAGNOSTICS menu (continued)
Manual Test Mode
Provides details on manual testing of boiler components and functions.
MAINTENANCE, DATE AND TIME menus
MAINTENANCE INFO
Fields for entering contractor and boiler service information.
SET TIME AND DATE
Instructions for setting the system's current date and time.
Startup — fill the system
Clean system to remove sediment
Procedure for flushing the system to remove debris.
Water chemistry
Requirements for system water pH and hardness.
Fill and test water system
Steps for filling and testing the boiler and system with water.
Startup — fill the system (continued)
Purge air from water system
Steps for removing air from the hydronic system.
Check/verify water chemistry
Verifying water parameters after filling and leak testing.
Startup — final checks
Check thermostat circuit(s)
Verifying thermostat wiring and operation.
Inspect/fi ll condensate system
Checking and filling the condensate trap and lines.
Final checks before starting boiler
A checklist of critical items before initial boiler startup.
Startup procedure
To start the boiler
Step-by-step instructions for initiating boiler operation.
Check flame & combustion with instruments
Procedure for verifying flame quality and combustion parameters.
Gas valve adjustment procedure
Guidance for adjusting gas valve settings for optimal combustion.
Startup procedure (continued)
Adjust valve at high fire
Steps to adjust the gas valve for high fire combustion settings.
Adjust valve at low fire
Steps to adjust the gas valve for low fire combustion settings.
Startup procedure (continued)
Check gas input rate
Procedure to measure and verify the natural gas input rate.
Verifi cation check list
A comprehensive checklist for final startup verification.
Annual startup and maintenance schedule
Service technician
Recommended annual maintenance tasks for service technicians.
Owner maintenance
Recommended daily, monthly, and periodic maintenance for owners.
Annual startup
HANDLING CERAMIC FIBER MATERIALS
Safety precautions for handling ceramic fiber materials.
FIRST-YEAR SPECIAL INSPECTION
Requirements for the initial year inspection of the boiler.
Annual startup (continued)
Check all piping for leaks
Procedure for inspecting all piping for leaks.
Check water system
Verifying system components are installed and operational.
Annual startup (continued)
Check expansion tank
Instructions for inspecting and verifying the expansion tank.
Inspect ignition electrode / flame sense rod
Procedure for inspecting and cleaning the ignition electrode.
Annual startup (continued)
Check all boiler wiring
Inspecting all boiler wiring for condition and security.
Check burner flame
Procedure for checking and evaluating the burner flame.
Annual startup (continued)
Check flame signal
Verifying the flame signal strength and its implications.
Check flue gas temperature
Verifying flue gas temperature relative to return water temperature.
Check blower speeds
Verifying blower speeds at different firing rates.
Troubleshooting
Before troubleshooting
General precautions and tool recommendations for troubleshooting.
Troubleshooting (continued)
Check the following
Initial checks for space heating, DHW, and BMS systems.
Always check Control module fuses
Instructions for checking and replacing control module fuses.
Troubleshooting (continued)
Control fault indications
Explains how fault conditions are displayed and managed by the control.
Troubleshooting (continued)
RESET TO FACTORY DEFAULT
Procedure for resetting control settings to factory defaults.
Control Error Condition Log
How to access and interpret recorded boiler faults and errors.
Troubleshooting (continued)
Control Fault Displays, Diagnostics and Suggested Corrective Actions
A table detailing common faults and their remedies.
Troubleshooting (continued)
Control Fault Displays, Diagnostics and Suggested Corrective Actions
Continues the table of faults and corrective actions.
Troubleshooting (continued)
Control Fault Displays, Diagnostics and Suggested Corrective Actions
Continues the table of faults and corrective actions.
Troubleshooting (continued)
Control Fault Displays, Diagnostics and Suggested Corrective Actions
Continues the table of faults and corrective actions.
Troubleshooting (continued)
Control Fault Displays, Diagnostics and Suggested Corrective Actions
Continues the table of faults and corrective actions.
Maintenance
Disconnect power before servicing
Safety warning to disconnect power before maintenance.
Clean the heat exchanger when required — water side
Procedure for cleaning the heat exchanger's water side.
Maintenance (continued)
Re-install cover plate
Instructions for reinstalling the burner/heat exchanger cover plate.
Re-install venturi/blower/mixing tube assembly
Steps to reinstall the venturi, blower, and mixing tube.
Replacement parts
Figure 91 Miscellaneous parts and kits
Lists various replacement parts and kits with part numbers.
Dimensions
Figure 98 Dimensional data — SVF 750
Provides detailed dimensions for the SVF 750 model.
Dimensions (continued)
Figure 99 Dimensional data — SVF 1000/1100
Provides detailed dimensions for the SVF 1000/1100 models.
Ratings — SVFTM Series 1 boilers
Figure 100 Ratings and engineering data
Presents AHRI certified ratings, DOE data, and specifications.
Figure 101 Derate due to vent/air piping length
Explains how vent/air piping affects boiler derating.
Installation and Service Certificate
Boiler Model Series CP Number Date Installed
Form for recording installation details and installer information.
Installation and Gas Boiler Data Collection Sheet
Boiler Settings
Section for recording various boiler configuration parameters.
Installation and Gas Boiler Data Collection Sheet
Priority 2 Settings, Priority 3 Settings, Priority 4 Settings
Sections for recording priority-specific settings.
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