WEIL-McLAIN SVF 725 Boiler User Manual

WEIL-McLAIN SVF 725 Boiler

Part 1 – General

Submittals

• The contractor must submit, promptly, all submittals for approval to the engineer.
• Under no circumstances will the contractor install any materials until the engineer has made final approval on the submittals.
• Product data and drawings must be submitted to the engineer for approval and must consist.
  1. General assembly drawing of the boiler including product description, model number, dimensions, clearances, weights, service sizes, etc.
  2. Schematic flow diagram of the boiler’s gas valve train(s).
  3. A schematic wiring diagram of the boiler’s control system that shows all components, interlocks, etc. and must identify factory wiring and field wiring.
  4. Full Function Factory Fire Test must be performed and documented on the boiler’s fire test label. Boiler start-up must be completed before final acceptance by the engineer.
  5. Operation and Maintenance Manuals must be submitted before final acceptance by the engineer and must contain shop drawings, product data, operating instructions, cleaning procedures, replacement parts list, maintenance and repair data, etc.

Quality Assurance

• The equipment must, at a minimum, be in strict compliance with the requirements of this specification must perform as specified and must be the manufacturer’s standard commercial product unless specified otherwise.
• Electrically operated components specified are to be “Listed” and/or “Labeled” as defined by NFPA 70, Article 100.
• The boiler must bear an ASME “H” stamp by ASME Section IV.
• The boiler must be CSA certified to the ANSI Z21.13 / CSA 4.9 standard for Gas Fired Low-Pressure Steam and Hot Water Boilers and must bear an authorized CSA rating label.
• Boiler must be AHRI-listed and certified by the Commercial Boiler program and the BTS-2000 testing standard.
• The boiler must undergo a Full Function Factory Fire Test and bear a fire test label.
• The boiler must be registered through the National Board from the factory manufacturer and must make available, upon request, all quality assurance documentation and results of the Full Function Factory Fire Test based on the boiler’s serial number.

Coordination

• Equipment must be handled, stored and installed according to the manufacturer’s instructions.
• Boiler start-up must be completed after all appliance connections are completed, e.g. gas piping, hydronic piping, and exhaust venting & electrical.

Warranty

• The boiler manufacturer must warrant each boiler, including boiler, trim, boiler control system, and all related components, accessories, and appurtenances against defects in workmanship and material for twelve (12) months from the date of startup, provided that the startup is completed within six (6) months of shipment.
• The boiler manufacturer must warrant the boiler’s heat exchanger for ten (10) years from the date of startup, provided that startup is completed within six (6) months of shipment.
• The boiler manufacturer must also warrant the boiler’s heat exchanger against failure due to thermal shock for ten (10) years from the date of startup, provided that the startup is completed within six (6) months of shipment.

Certification

• Manufacturer’s Certification – The boiler manufacturer must certify the following:
  1. The products and systems furnished are in strict compliance with the specifications.
  2. The boiler, burner and other associated mechanical and electrical equipment have all been properly coordinated and integrated to provide a complete and operable boiler.
  3. The boiler must comply with ANSI Z21.13 / CSA 4.9 (latest edition).
  4. The boiler must be CSA certified for at least 97% efficiency based on operating conditions specified for testing under ANSI Z21.13 / CSA 4.9.
  5. The boiler must be AHRI certified for at least 96% efficiency based on operating conditions specified for testing under BTS-2000.
  6. The boiler must comply with ASME Section IV (latest edition).
  7. The boiler must comply with ASME CSD-1 (latest edition).
  8. The boiler’s H-3 form must be registered with the National Board.
• Contractor’s Certification – The installing contractor must certify the following:

The products and systems installed are in strict compliance with the specifications and all applicable local and/or state codes. The specified field tests have been satisfactorily performed by a factory-authorized startup agent. The equipment furnished contains inter-changeable parts with the specified equipment so that all major equipment parts can be obtained from the specified manufacturer.

Part 2 – Product

Manufacturers

• Furnish and install factory “packaged” low-pressure hot water boiler(s) as manufactured by Weil-McLain or as approved and accepted by the Engineer as defined in the table below:
  

  Model Number	Fuel Type	Vent Category	Max Input High Fire (BTU/Hr)	Min Input Low Fire (BTU/Hr)	Turndown Ratio	Max Output (BTU/Hr)	Efficiency
  SVF 725	NG	II or IV	725,000	73,000	10:1	708,000	97.7%
  SVF 850	NG	II or IV	850,000	73,000	12:1	820,000	97.5%

• Each factory “packaged” boiler must be complete with all components and accessories necessary for a complete and operable boiler as hereinafter specified.
• Each boiler must be furnished factory-assembled with the required wiring and piping as a self-contained unit. Each boiler must be readily transported and ready for installation.
• All “Approved Equal” or “Approved Alternate” boilers must demonstrate compliance with the requirements of this specification.

Components

Cabinet Enclosure

1. Each boiler must feature a fully assembled cabinet enclosure fabricated from Carbon Steel or Aluminum sheet metal (minimum 16 Gauge) with a powder coat finish.
2. The boiler’s cabinet enclosure must not exceed 35” in width and the completed boiler must fit through a standard double doorway.
3. The boiler’s cabinet enclosure must feature removable access panels/doors that can be easily opened.
4. The boiler’s cabinet enclosure must eliminate the use of refractory or other insulating materials by baffling the combustion air around the heat exchanger and the outer surface temperature must not exceed 20°F above ambient temperature. The boiler’s cabinet enclosure must prominently display all required safety, instruction, compliance and factory runout labels.

Heat Exchanger

1. Each fire-tube boiler must contain an ASME Section IV heat exchanger with an “H” stamp designed for a maximum allowable working pressure of 160 PSIG and a maximum allowable temperature of 210°F.
2. The completed heat exchanger must consist of welded 316L SS helical-fired tubes and provide no less than the total fireside heating surface area defined in the table below. Each completed heat exchanger must include an integral stainless-steel condensate pan/collector, condensate drain, removable burner assembly, inlet temperature sensor, outlet temperature sensor, flue gas temperature sensor, heat exchanger temperature sensor, automatic air vent, thermowell for high-temperature limit capillary, low water cutoff probe or flow switch, and all necessary assembly hardware.
3. Each stainless-steel heat exchanger must be designed to maintain water turbulence at the full published range of acceptable flow rates at various boiler conditions as described below:
   

   	SVF 725	SVF 850
   Heating Surface Area	99.88 ft.²	99.88 ft.²

   • The maximum allowable flow rate will generate a 20°F ΔT when the boiler is operating at full capacity.
   • The minimum allowable flow rate will generate a 70°F ΔT when the boiler is operating at full capacity.
4. The boiler’s completed heat exchanger must be capable of operating with a minimum outlet water temperature of 42°F.
5. Each heat exchanger must be hydrostatically tested by the manufacturer to a minimum of 1-1/2 times the maximum allowable working pressure for a minimum of 5 minutes. During this hydrostatic pressure test, the operator will inspect the pressure gauge and visually verify there are no water leaks.

Main Gas Train

1. Boilers configured for single-fuel operation must be equipped with an integral main gas valve train capable of burning Natural G
2. Each gas valve train must include at least the following:
   • One (1) upstream manual shutoff valve for field-connection.
   • One (1) combination Air-Gas ratio control and safety shutoff valve with dual solenoids (in-series) that can be independently energized for leak testing and integrated into a single-body design.
   • The combination gas valve must operate as a “Zero Governor” and control a neutral gas pressure inside the gas valve.
   • One (1) low gas pressure switch (manual reset).
   • One (1) high gas pressure switch (manual reset).
   • Two (2) gas pressure test ports.
   • One (1) downstream manual shutoff valve.
3. Each gas train must be completely independent and include dedicated safety devices, shutoff valves, etc. Each gas train must be individually identified by the manufacturer with labels and dedicated paint colours (Yellow = Natural Gas ).
4. The main gas valve train(s) must be factory assembled, piped, and wired and allow for operation at full rated boiler capacity from 3.5 – 4.0” W.C. up to the maximum inlet gas pressure of 14.0” W.C.
5. If the supplied gas pressure exceeds 14” W.C., the contractor must supply a suitable intermediate gas pressure regulator of the lock-up type to reduce the gas pressure to acceptable levels.

Power Burner

1. The boiler manufacturer must furnish an integral power-type fuel burner with each boiler. The complete power fuel burner assembly must consist of a gas burner, combustion air blower, main gas valve train, and ignition system. The burner manufacturer must fully coordinate the burner design with the boiler’s heat exchanger and the boiler control system to provide the required capacities, efficiencies, and performance specified. Boilers shipped without a power burner and field-equipped with a 3rd party power burner are not acceptable.
2. The burner must be a single burner, fully modulating, with dynamic air density compensation control.
3. The burner must incorporate a fuel/air ratio control system to preserve exhaust oxygen levels as per boiler schedule, maintaining consistent flue dew point.
4. The system must be linkage-less without the use of electronic control loops and electronic oxygen sensors requiring calibration and renewal.
5. Low NOx burner must be certified by SCAQMD for NOx levels listed on the schedule when O2 is corrected to 3%. No additional setup or adjustment, such as increasing excess air, will be necessary to achieve the level listed Each burner must be installed vertically inside the combustion chamber with combustion gases flowing downward through the heat exchanger. The burner must consist of a stainless steel flange and a perforated stainless steel cylinder.
6. Each boiler must be equipped with direct spark ignition. The main flame must be monitored and controlled by a flame rod/ionization probe (rectification) system.

Boiler Safety & Trim Devices

1. The boiler manufacturer must furnish and test the following safety and trim devices with each boiler:
   • Safety relief valves must be provided in compliance with the ASME code.
   • The contractor is required to pipe the relief valve discharge piping to an acceptable drain.
   • Water pressure/temperature gauge.
   • Low Water / Flow cutoff.
   • Manual reset high-limit water temperature controller.
   • Operating temperature control to control the sequential operation of the burner.
   • High and Low Gas Pressure switches.
   • Flame rod/ionization probe flame detection.
2. The boiler manufacturer must provide a CSD-1 form identifying each safety and trim device.
3. The boiler must be capable of interfacing with the following external safety devices:
   • Auxiliary Low Water Cutoff device.
   • Combustion Air Damper End Limit Switch.
   • Emergency Stop (E-Stop) switch.
   • External Safety Device w/ contact closure.

Each boiler must be provided with all necessary controls, all necessary programming sequences, and all safety interlocks. Each boiler control system must be properly interlocked with all safeties. Each boiler must be provided with a “Full Modulating” firing control system whereby the firing rate is infinitely proportional at any firing rate between low-fire and high-fire as determined by the pulse width modulation input control signal. Both fuel input and air input must be sequenced in unison with the appropriate firing rate without the use of mechanical linkage. The boiler’s control system must provide the minimum capabilities:

• 7” colour touchscreen display with one or more USB ports.
• Standard on-board Ethernet port for wired internet connectivity.
• Parameter uploads and downloads via external USB flash drive.
• Software updates via external USB flash drive.
• Capture screenshots from the control’s display by saving digital image files to an external USB flash drive.
• Local Representative Screen can be programmed to provide contact information for the local boiler manufacturer’s representative.
• Programmable Relay Outputs for direct control of pumps, control valves, dampers and other auxiliary devices.
• Multiple boiler “cascade” network up to 32 boilers without any external control panel. The installation of external sequencing control panels is not acceptable.
• Automatic hybrid system control for multiple boiler “cascade” systems with both condensing and non-condensing boilers.
• This control logic prioritizes condensing boilers at low water temperatures and prioritizes non-condensing boilers at high water temperatures.
• Auxiliary Boiler Relay for multiple boiler “cascade” systems which can be used to enable a 3rd party boiler platform in the event the “cascade” system is unable to satisfy the heating load.
• Programmable Boiler and System pump control with modulating capabilities for multiple boiler “cascade” systems installed in a primary secondary piping arrangement.
• Programmable Control Valve logic with modulating capabilities for multiple boiler “cascade” systems installed in a Primary-Only piping arrangement.
• Programmable synchronization of exhaust fan timing to equal the real-time burner firing rate.
• 5 Pre-installed PID control speeds for system optimization in addition to a user-defined PID function capability.
• Integration with external Building Management Systems (BMS) via MODBUS® RTU protocol.
  NOTE: Optional Protocol Converter for communication via LONWORKS® and BACnet® must be available for purchase from the boiler manufacturer.
• Hardwire integration with Building Management Systems (BMS) via 4-20mA analog control signal for temperature or firing rate control.
• Intuitive “Setup Wizards” ask the user a series of questions and allow for step-by-step configuration of the boiler operation, control, and connectivity.
• On-screen error notifications with a comprehensive description of all alarm conditions and several troubleshooting steps.
• Automatic flue gas temperature and outlet (supply) temperature compensation to prevent over-firing of the boiler equipment.
• Automatic differential temperature compensation to prevent over-firing of the boiler equipment in a low flow condition.
• Automatically adjust the temperature set point and shut down the boiler based on the outdoor air temperature conditions.
• Night Setback functionality via external point of closure (or BMS integration) for unique “Occupied” and “Unoccupied” temperature set point values.
• Setback feature will include the ability to schedule multiple adjustments within 24 hours for building optimization.
• Boosted boiler operation resulting in a pre-determined, timed, increase in boiler temperature setting in an unexpected occupied mode.
• Maintain a single temperature set point with a minimum outlet (supply) water temperature of 42°F up to a maximum outlet (supply) water temperature of 194°F.
• On-board DHW Priority is capable of a seamless transition between Comfort Heat (CH) and Domestic Hot Water (DHW) operation.
• On-board CH&DHW operation for simultaneous Comfort Heat (CH) and Domestic Hot Water (DHW) operation.
• Alarm Relay Output to announce alarm conditions that require manual reset on the master or any member boiler from a single boiler source.
• Programmable Low Fire Delay to prevent excessive short cycling of the boiler equipment.
• Local Manual Operation.
• The boiler control system must be capable of interfacing with the following external control devices:
• Building Management System (MODBUS®). NOTE: Optional Protocol
• Converter for communication via LONWORKS® and BACnet® must be available for purchase from the boiler manufacturer.
• Domestic Hot Water Break-on-Rise Aquastat (Normally Closed).
• Domestic Hot Water Tank Temperature Sensor (12kΩ).
• External Header Temperature Sensor (12kΩ).
• Outdoor Air Temperature Sensor (12kΩ) both wired and wireless.

Part 3 – Boiler Installation

Installation

• Installation must be performed by the contractor according to the requirements of the applicable codes.
• The contractor must review the boiler and installation for compliance with requirements and/or issues that may affect boiler performance. Installation should not proceed until unsatisfactory conditions have been corrected.
• The contractor must mount the equipment as described below:
  • Install boilers on cast-in-place concrete equipment base in compliance with the requirements defined in the manufacturer boiler manual.
  • The contractor must install gas-fired boilers by NFPA 54/ANSI Z223.1 (United States), or CAN/CSA B/149.1 (Canada).
  • The contractor must install gas-fired boilers by NBIC – Part 1 (Installation), or another installation code having local jurisdiction.
  • The contractor must assemble and install any external boiler safety/trim devices.
  • The contractor must install any electrical devices furnished with the boiler, but not specified to be factory-mounted.
  • The contractor must install control wiring to field-mounted electrical devices according to the requirements of NFPA 70.
  • The contractor must install electrical (power) wiring to the boiler by the requirements of NFPA 70.

Connections

Gas Piping

1. Each boiler must be provided with all necessary gas connections. Refer to the boiler’s specification sheet or manual for connection sizes.
2. Install gas piping by NFPA 54/ANSI Z223.1 (United States), or CAN/CSA B/149.1 (Canada).

Hydronic Piping

1. Each boiler must be provided with all necessary inlet (supply) and outlet (return) connections. Refer to the boiler’s specification sheet or manual for connection sizes.
2. Check the manufacturer’s installation manual for clearance dimensions and install piping that will allow for service and ease of maintenance.
3. Install piping from the equipment drain connection to the nearest floor drain. Piping must be at least full size of connection and adhere to proper codes for neutralization.

Exhaust Venting

1. The boilers must be dual-certified as Category II or IV appliances and are capable of operating with a slightly negative to slightly positive exhaust vent pressure and the vent gas temperature is likely to cause condensate production in the vent.
2. Install the exhaust/flue venting system by NFPA 54/ANSI Z223.1 (United States), or CAN/CSA B/149.1 (Canada) and per the manufacturer’s recommendations in the installation manual.

Air Inlet

1. The boilers must be certified for Direct Vent / Sealed Combustion installations where the combustion air is supplied directly to the boiler through ductwork.
2. Install the air inlet system by NFPA 54/ANSI Z223.1 (United States), or CAN/CSA B/149.1 (Canada) and per the manufacturer’s recommendations in the installation manual.

Electrical

1. Install an external disconnect and overload protection for each boiler under the requirements of NFPA 70.
2. The voltage requirements for each boiler must be configured for: SVF725/850: 120VAC, Single-Phase, 60Hz
3. The amperage requirements for each boiler are described in the table below:
   

   	SVF 725	SVF 850
   Internal Overload Protection	10 Amps	10 Amps
   Recommended Circuit Capacity	10 Amps	10 Amps

SVF 725-850 Guide Specification

Documents / Resources

WEIL-McLAIN SVF 725 Boiler [pdf] User Manual SVF 725 Boiler, SVF 725, Boiler

References

• User Manual