INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
SCG™
GAS - FIRED BOILER
As an ENERGY STAR® Partner, Burnham Hydronics has determined that the SCG meets the ENERGY
STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA).
For service or repairs to boiler, call your heating contractor. When seeking information on
boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
Boiler Serial Number
Installation Date
SCG
Heating Contractor
Phone Number
Address
8140705R9-10/08
Price - $5.00
WARNING
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an experienced, skilled, and
knowledgeable installer or service agency.
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efficiency.
Installation is not complete unless a pressure relief valve is installed into the tapping located on top of
appliance. - See the Water Piping and Trim Section of this manual for details.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
Boilermaterialsofconstruction,productsofcombustionandthefuelcontainalumina,silica,heavymetals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the appliance.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instruc-
tions, including all those contained in component manufacturers manuals which are provided with the
boiler before installing, starting up, operating, maintaining or servicing.
Keep boiler area clear and free from combustible materials, gasoline and other flammable vapors or
liquids.
All cover plates, enclosures and guards must be in place at all times.
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility
of the installing contractor to see that all controls are correctly installed and are operating properly when the
installation is complete.
ꢁ
Table of Contents
I. Pre-Installation...............................6
VI. Electrical.......................................53
VII. Modular Installation ....................62
VIII. System Start-up ............................64
IX. Service ..........................................71
X. Repair Parts..................................78
II. Unpack Boiler ................................7
III. Venting/Air Intake Piping ..............8
IV. Water Piping and Trim .................45
V. Gas Piping....................................50
Figure 1: Minimum Clearances to Combustibles
4
5
I. Pre-Installation
F. Provide combustion and ventilation air in accordance
with applicable provisions of local building codes,
or: USA - National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation;
Canada - Natural Gas or Propane Installation Code,
CAN/CSA-B149.1.
WARNING
If you do not follow these instructions exactly,
a fire or explosion may result causing property
damage or personal injury.
WARNING
DANGER
Adequate combustion and ventilation air must
be provided to assure proper combustion.
Do not install boiler where gasoline or other
flammable vapors or liquids, or sources of
hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.
The following guideline is based on the National Fuel Gas
Code, NFPA 54/ANSI Z223.1.
1. Determine volume of space (boiler room). Rooms
communicating directly with space (through
openings not furnished with doors) are considered
part of space.
NOTICE
Due to the low water content of the boiler, mis-
sizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Burnham
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler to
the system. Modular boiler installations greatly
reduce the likelihood of boiler oversizing.
Volume [ft³] = Length [ft] x Width [ft] x Height [ft]
2. Determine Total Input of all appliances in space.
Round result to nearest 1,000 Btu per hour (Btuh).
3. Determine type of space. Divide Volume by Total
Input.
a. If result is greater than or equal to 50 ft³ per
1,000 Btuh, space is considered an unconfined
space.
A. Installation must conform to the requirements of the
authority having jurisdiction. In the absence of such
requirements, installation must conform to the National
Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/
CSA B149.1 Installation Codes.
b. If result is less than 50 ft³ per 1,000 Btuh, space
is considered a confined space.
4. Determine building type. A building of unusually
tight construction has the following characteristics:
B. Appliance is design certified for installation on
combustible flooring. Do not install boiler on
carpeting.
a. Walls and ceiling exposed to outside atmosphere
have a continuous water vapor retarder with a
rating of 1 perm or less with openings gasketed
and sealed, and;
C. Provide clearance between boiler jacket and
combustible material in accordance with local fire
ordinance. Refer to Figure 1 for minimum listed
clearance from combustible material. Recommended
service clearance is 24 inches from left side, right
side and front. Service clearances may be reduced to
minimum clearances to combustible materials.
b. Weather-stripping has been added on openable
windows and doors, and;
c. Caulking or sealants applied in joints around
window and door frames, between sill plates and
floors, between wall-ceiling joints, between wall
panels, at plumbing and electrical penetrations,
and at other openings.
D. Install on level floor. For basement installation provide
solid base such as concrete, if floor is not level or if
water may be encountered on floor around boiler. Floor
must be able to support weight of boiler, water and all
additional system components.
5. For boiler located in an unconfined space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally
provided by fresh air infiltration through cracks
around windows and doors.
E. Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
ꢂ
c. Horizontal ducts. Minimum free area of one (1)
square inch per 2,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
NOTICE
Boilers operated with direct vent (sealed
combustion) are exempt from needing provisions
for combustion air from the room, provided
air intake piping is installed per Code and the
instructions in the manual.
Alternate method for boiler located within
confined space. Use indoor air if two permanent
openings communicate directly with additional
space(s) of sufficient volume such that combined
volume of all spaces meet criteria for unconfined
space. Size each opening for minimum free area
of one (1) square inch per 1,000 Btu per hour
input of all equipment in spaces, but not less than
100 square inches.
6. For boiler located within unconfined space in building
of unusually tight construction or within confined
space, provide outdoor air through two permanent
openings which communicate directly or by duct
with the outdoors or spaces (crawl or attic) freely
communicating with the outdoors. Locate one opening
within twelve (12) inches of top of space. Locate
remaining opening within twelve (12) inches of bottom
of space. Minimum dimension of air opening is three
(3) inches. Size each opening per following:
7. Combustion Air/Ventilation Duct Louvers and
Grilles. Equip outside openings with louvers to
prevent entrance of rain and snow, and screens to
prevent entrance of insects and rodents. Louvers and
grilles must be fixed in open position or interlocked
with equipment to open automatically before burner
operation. Screens must not be smaller than ¼ inch
mesh.
a. Direct communication with outdoors. Minimum
free area of one (1) square inch per 4,000 Btu per
hour input of all equipment in space.
Consider the blocking effect of louvers, grilles and
screens when calculating the opening size to provide
the required free area. If free area of louver or grille
is not known, assume wood louvers have 20-25
percent free area and metal louvers and grilles have
60-75 percent free area.
b. Vertical ducts. Minimum free area of one (1)
square inch per 4,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.
CAUTION
If using indoor air for combustion (see Venting Section - Indoor Air), avoid operating this boiler in an
environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated
under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper
operation.
II. Unpack Boiler
WARNING
CAUTION
Installation of this boiler should be undertaken
only by trained and skilled personnel from a
qualified service agency.
Do not drop boiler. Do not bump boiler jacket
against floor.
A. Move boiler to approximate installed position.
E. Tilt the boiler to its front side or back side and slide a
B. Remove all crate fasteners.
wooden slat under the three raised feet.
C. Lift and remove outside container. Save two of the
wooden slats from the container sleeve for use in Steps
E and F.
F. Tilt the boiler in the opposite direction and slide
another wooden slat under the three raised feet.
G. Slide the boiler left or right off the skid using the two
D. Remove all boiler hold-down fasteners.
wooden slats as runners.
H. Move boiler to its permanent location.
7
III. Venting / Air Intake Piping
WARNING
Do not use this boiler with galvanized, Type ꢁ04 or Type ꢁ1ꢂ stainless steel, non metallic or any other
non Alꢀ9-4C® based vent systems.
Do not use a barometric damper or drafthood with this appliance.
Do not use vent dampers with this boiler.
Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should
be in good repair (sealed, painted, etc.).
This appliance needs fresh air for safe operation and must be installed so there are provisions for
adequate combustion and ventilation air.
Do not reduce size of air intake pipe.
Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation
instructions of this manual.
Do not operate appliance where gasoline or other flammable vapors or liquids, or sources of hydro-
carbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used,
stored and/or present in the air.
When installing vent pipe through chimney, no other appliance can be vented into the chimney.
Do not exceed maximum vent/air intake lengths. Refer to Table 4.
TABlE 1: AIR INTAkE / VENT SySTEM OPTIONS
Installation
Drawing and
Specification
(See Section)
Additional
Vent Kit
Required
Option
Description
Part Number
Direct Vent (sealed combustion) with both the vent pipe and
air intake pipe terminating horizontally (through a sidewall)
with individual penetrations for the vent and air intake piping
and terminals.
1. Separate
No
No
See Table 2
See Table 2
D.
E.
F.
Horizontal
Direct Vent (sealed combustion) with both the vent pipe and
air intake pipe terminating vertically (through the roof) with
individual penetrations for the vent and air intake piping and
terminals.
2. Separate
Vertical
Direct Vent (sealed combustion) with the vent pipe and air
3. Combination intake pipe joining at a common terminal and terminating
3 - 6 Section
(61106012)
Yes
Horizontal
horizontally (through a sidewall up to 15” thick) with only
one penetration.
3 - 4 Section
(100222-01)
Direct Vent (sealed combustion) with the vent pipe and air
intake pipe joining at a common terminal and terminating
vertically (through the roof) with only one penetration.
4. Combination
Yes
G.
Vertical
5 - 6 Section
(100223-01)
Power Vent - Air used for combustion is provided from within
the building.
5. Indoor Air
No
No
-----
H.
I.
Direct Vent (sealed combustion) with both the vent pipe and
air intake pipe terminating horizontally (through a sidewall)
with individual penetrations for the vent and air intake piping
and terminals.
6. Optional
Separate
See Table 2
Horizontal
8
TABlE ꢀ: VENT SySTEM COMPONENTS INClUDED WITh BOIlER
Vent System Components
Part Number
8110701
Gasketed Vent Terminal 3” Horizontal
(SCG-3 thru SCG-7)
Gasketed Vent Terminal 4” Horizontal
(SCG-8 & SCG 9)
8110702
6116045
6116044
6116063
Disc Air Intake - 3”
(SCG-3 & SCG-4)
Disc Air Intake - 4”
(SCG-5 & SCG-6)
Air Intake - 5”
(SCG-7 thru SCG-9)
TABlE ꢁ: BURNhAM VENT SySTEM AND AIR INTAkE SySTEM COMPONENTS
Equivalent
Vent System Component Part Number
Feet of Pipe
3” Dia. Pipe x 1 Ft
4” Dia. Pipe x 1 Ft
3” Dia. Pipe x 3 Ft
4” Dia. Pipe x 3 Ft
3” Dia. Pipe x 5 Ft
4” Dia. Pipe x 5 Ft
3” Dia. Pipe x Adjustable
8116296U
100176-01
8116298U
100177-01
8116300U
100178-01
8116319U
1
3
5
Intake System Components
Equivalent
Feet of Pipe *
(Parts by Others)
Equal to
Installed Length
(1.06 TO 1.64)
3”, 4”, or 5” ID Pipe x 1 Ft
3”, 4”, or 5” ID Pipe x 2 Ft
3”, 4”, or 5” ID Pipe x 4 Ft
3”, 4”, or 5” ID Pipe x 5 Ft
3”, or 4” 90° Elbow
1
2
4
5
5
5
6
6
4” Dia. Pipe x Adjustable
100179-01
3” Dia. 90° Elbow
8116294U
100180-01
8116292U
100181-01
8116302U
100182-01
8116304U
100183-01
8116116
5
5
4” Dia. 90° Elbow
3” Dia. 45° Elbow
4” Dia. 45° Elbow
3”, or 4” 45° Elbow
3” Dia. Horizontal Drain Tee
4” Dia. Horizontal Drain Tee
3” Dia. Vertical Drain Tee
4” Dia. Vertical Drain Tee
3” Single Wall Thimble
4” Single Wall Thimble
3” Double Wall Thimble
4” Double Wall Thimble
5” 90° Elbow
2
5” 45° Elbow
* Equivalent Feet of Pipe Based on
Standard 4” Smoke Pipe Design
7½
---
---
100184-01
8116115
100185-01
TABlE 4: VENT/AIR INTAkE lENGTh
3” Air Intake Pipe 4” Air Intake Pipe 5” Air Intake Pipe
(Equiv. Ft.) (Equiv. Ft.) (Equiv. Ft.)
Min. Max. Min. Max. Min. Max.
3” Vent Pipe
(Equiv. Ft.)
4” Vent Pipe
(Equiv. Ft.)
Model
Min.
8
Max.
50
Min.
---
Max.
---
SCG-3 & SCG-4
SCG-5 & SCG-6
SCG-7
8
50
---
---
---
---
---
---
---
---
---
---
8
50
---
---
---
8
---
50
40
8
50
---
---
---
---
8
50
---
---
SCG-8 & SCG-9
8
---
---
8
40
9
A. Vent Guidelines Due to Removal of an Existing
Boiler
B. General Guidelines
1. Vent system installation must be in accordance
with National Fuel Gas Code, NFPA 54/ANSI
Z221.3 or applicable provisions of local building
codes. Contact local building or fire officials about
restrictions and installation inspection in your area.
For installations not involving the replacement of an
existing boiler, proceed to Step B.
When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the remaining
appliances. At the time of removal of an existing
boiler, the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation:
2. The SCG is designed to be installed as either
a Direct Vent boiler or Power Vent boiler. In
the Direct Vent configuration all of the air for
combustion is supplied directly to the burner
enclosure from outdoors and flue gases are vented
directly outdoors (through wall or roof). In the
Power Vent configuration, room air provides air
for combustion and ventilation. Flue gases are still
vented directly outdoors (through wall or roof).
Note: Venting requirements change if indoor air is
used.
1. Seal any unused openings in the common venting
system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and other
deficiencies which could cause an unsafe condition.
3. Refer to the appropriate drawings in this section of
this manual to determine the proper configuration of
venting system. See Table 1.
3. Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any appliance
not connected to the common venting system.
Turn on any exhaust fans, such as range-hoods and
bathroom exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
4. This appliance requires a Special Gas Vent. The
product is designed to use Burnham supplied
AL 29-4C® Stainless Steel vent system components.
The following manufacturers offer similar
AL 29-4C® components and are approved for use
with this product. Heat-Fab Inc. - Saf-T-Vent (800-
772-0739); Flex-L International Inc. - Star-34 (800-
561-1980); Z-Flex U. S., Inc. - Z-Vent (800-654-
5600); and Protech Systems, Inc.- FasNSeal™ (800-
766-3473) or equivalent. The use of these alternate
manufacturer’s venting systems will require
adapters to connect to the Burnham supplied vent
connector and vent terminal. These adapters are not
supplied with this unit and should be obtained from
the supplier of the alternate manufacturer’s venting
system. See Table 3 for complete list of Burnham
Vent System Components.
4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening
after five (5) minutes of main burner operation. Use
the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
5. Horizontal vent pipe must maintain a minimum ¼
inch per foot slope down towards boiler.
6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas burning appliance to their previous
conditions of use.
6. Use noncombustible ¾ inch pipe strap to support
horizontal runs and maintain vent location and
slope while preventing sags in pipe. Do not restrict
thermal expansion or movement of vent system.
Maximum support spacing is five (5) feet. Do not
penetrate any part of the vent system with fasteners.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. When resizing any portion of the
common venting system, the common venting
system should be resized to approach the minimum
size as determined using the appropriate tables in
Part II in the National Fuel Gas Code, NFPA 54/
ANSI Z223.1.
7. Vent length restrictions are based on equivalent
length of vent/air pipe (total length of straight
pipe plus equivalent length of fittings). Maximum
vent/air lengths are listed in Table 4. Do not exceed
maximum vent/air intake lengths. Table 3 lists
equivalent lengths for fittings. Do not include vent/
air terminals in equivalent feet calculations.
8. Provide and maintain vent pipe minimum clearances
to combustible materials. Vent pipe minimum
clearance to combustible material is four (4) inches
when vent is installed in a fully enclosed (chase)
application or three (3) inches when vent is installed
10
11. Plan venting system to avoid possible contact with
plumbing or electrical wires. Start at vent connector
on top of boiler and work towards vent terminal.
with at least one side open, similar to a joist bay
application. Use double wall thimble [Burnham
Part No. 8116115 (3”), 100185-01 (4”)] when
penetrating a combustible wall.
12. Once a vent pipe manufacturer and system is chosen
never mix and match vent systems.
9. Do not install venting system components on
the exterior of the building except as specifically
required by these instructions. The vent termination
location is restricted as follows:
13. If a non-standard length pipe is required:
Gasketed Vent System: The use of the adjustable
length pipe (P/N 8116319U) is recommended to
complete a non-standard pipe length. This pipe
requires a minimum installed length of 12¾ inch
and can adjust across a 7 inch gap up to a maximum
of 19¾ inch long. (Note for the adjustable pipe
the installed length should be measured from the
centerline of the bead on the male end of the first
pipe to the end of the female pipe excluding the
locking band of the second pipe with a single
gasket.) Only in the event the adjustable length pipe
is not sufficient a standard length pipe may be cut
using the procedure outlined below for the Gasket-
Less Vent System.
a. Minimum twelve (12) inches above grade plus
normally expected snow accumulation level, or
seven (7) feet above grade if located adjacent
to public walkway. Do not install over public
walkway where local experience indicates
appliance flue gas vapor or condensate creates a
nuisance or hazard.
b. Minimum three (3) feet above any forced air
inlet located within ten (10) feet.
c. Direct Vent - Minimum one (1) foot below, one
(1) foot horizontally from, or one (1) foot above
any door, window, or gravity air inlet.
Power Vent - Minimum four (4) feet below, four
(4) feet horizontally from, or four (4) feet above
any door, window, or gravity air inlet.
WARNING
Never exceed maximum installed length of 19¾
inches for adjustable length pipe.
d. Minimum four (4) feet horizontally from electric
meters, gas meters, regulators, and relief valves.
This distance may be reduced if equipment is
protected from damage due to condensation or
vapor by enclosure, overhangs, etc.
Risk of flue gas leakage is possible.
NOTICE
e. Minimum twelve (12) inches from overhang or
corner of building.
Cut must be square with pipe and filed or
sanded smooth before joining. Carefully ensure
roundness of cut pipe by hand with gloves before
installing. Seal joint with RTV specified in this
manual.
10. Enclose vent passing through occupied or
unoccupied spaces above the boiler with material
having a fire resistance rating of at least equal to the
rating of the adjoining floor or ceiling. Maintain
minimum clearances to combustible materials. See
Figure 1.
C. Install Vent Pipe, Burnham Gasketed Vent System.
1. Procedure for Joining Burnham Gasketed Vent Pipe
and Fittings. See Figure 3.
Note: For one or two family dwellings, fire
resistance rating requirement may not need to be
met, but is recommended.
Figure ꢁ: Burnham Gasketed Vent Joint Detail
11
a. Wipe the male end of each joint using an alcohol
pad to remove any dirt and grease.
Air Intake piping - See Figures 4A, 4B, 5A and 5B.
8. Locate air intake termination on the same wall as
the vent termination if possible, to prevent nuisance
boiler shutdowns. However, boiler may be installed
with vertical venting and sidewall combustion air
inlet or visa versa, if installation conditions do not
allow alternate arrangement.
b. Align weld seams in pipes and use a slight
twisting motion to FULLY insert male end into
female end of joint. Ensure bead in male end
of pipe is below locking band and rest against
the end of the female pipe. Verify the factory-
installed gasket is not dislodged or cut.
9. Do not exceed air intake length. See Table 4.
10. Use single wall metal or PVC pipe.
c. Tighten locking band by HAND with a 5/16”
nut driver until snug plus ¼ turn. DO NOT
SECURE JOINTS WITH SHEET METAL
SCREWS OR POP RIVETS. DO NOT
PUNCTURE THE VENT SYSTEM!
a. Air intake pipe diameter is based on boiler size.
SCG-3 & SCG-4 uses 3 inch diameter piping.
SCG-5 & SCG-6 uses 4 inch diameter piping.
SCG-7 thru SCG-9 uses 5 inch diameter piping.
d. Once the installation is complete, operate
appliance and inspect all joints to ensure that flue
gases and/or liquid condensate will not escape.
11. Air intake termination must be located:
Horizontal - At least twelve (12) inches above
grade plus the expected snow accumulation.
D. Separate Horizontal Venting System. See Figures
4A, 4B, 5A and 5B. See Figure 43 on Page 72 for
Blower Vent Connector Assembly.
12. Start at collar on boiler jacket and work towards the
air intake terminal.
Vent Piping –
13. Maintain minimum of ¼ inch per foot slope on
horizontal runs. Slope towards air inlet terminal
when possible. If not, slope towards boiler.
1. This boiler is supplied with components as standard
equipment for installation of the separate horizontal
venting system.
14. The air intake pipe must be adequately supported
with straps or supports no less than five (5) feet
apart on horizontal runs. The complete air intake
piping system must be rigid and able to withstand
minor impacts without collapse.
2. Do not exceed maximum vent/air intake lengths.
Refer to Table 4.
3. Recommended horizontal installation consists
of vent being sloped down ¼ inch per foot away
from boiler. See Figure 4A. See Figure 48 for an
alternate horizontal installation.
15. Inlet air pipe penetration:
Horizontal - Size wall penetration to allow easy
insertion of air inlet piping. Seal around pipe with
sealant to form weathertight exterior joint.
4. Use appropriate designed thimbles when passing
through combustible walls (thimble use optional for
noncombustible walls). Insert thimble through wall
from outside. Secure outside flange to wall with
nails or screws, and seal ID, OD and vent holes with
sealant material. Install inside flange to inside wall,
secure with nails or screws, and seal with sealant
material.
16. Seal all joints airtight, using silicone caulk or self-
adhesive aluminum tape.
17. Install Air Intake Terminal:
Horizontal - Remove four (4) screws from cover
plate and remove cover plate from terminal. Insert
intake piping into intake terminal collar. Secure
terminal to intake piping and seal joint with silicone
caulk or self-adhesive aluminum tape. Apply
continuous bead of silicone caulk around the back
of the intake terminal, approximately ¼ inch from
its edge. Push inlet terminal inward until terminal’s
back flange is against the wall surface. Secure the
terminal with noncorrosive fasteners (stainless steel,
brass or aluminum) to the wall. Reinstall the cover
plate with four (4) screws. Apply a bead of silicone
caulk to perimeter of intake terminal’s back flange
to provide a weathertight seal.
5. For noncombustible wall application when thimble
is not used, size opening such that bell with locking
band attached cannot pass through.
6. Join vent terminal to vent pipe. See Figures 5A and
5B.
7. Insert vent pipe through thimble/opening from
outside and join to vent system. Apply sealant
between vent pipe and opening/thimble to provide
weathertight seal.
1ꢀ
1ꢁ
14
15
1ꢂ
E. Separate Vertical Venting System - See Figures 6, 7, 8A, 8B and 9.
NOTICE
Roof penetrations require the use of roof flashing
and storm collar - not supplied with boiler.
Vertical Venting –
8. Locate air intake termination on the same roof
location as the vent termination if possible, to
prevent nuisance boiler shutdowns. However, boiler
may be installed with vertical venting and sidewall
combustion air inlet or visa versa, if installation
conditions do not allow alternate arrangement.
1. See Figure 43 on Page 72 for Blower Vent
Connector Assembly. Do not exceed maximum vent
lengths. Refer to Table 4.
2. Installation of a vertical vent drain tee 8116304U
is required on all vertical vent applications. See
Figures 6 and 7. Attach vertical vent drain tee
directly to elbow or horizontal pipe from an elbow
immediately after vent connector.
9. Use single wall metal pipe or PVC and fittings
available at most heating distributors.
a. Air intake pipe diameter is based on boiler size.
3. Slope horizontal runs minimum ¼ inch per foot.
Slope towards vertical vent drain tee. Position weld
seams in vent pipes, in all horizontal runs, at the top
to avoid condensate from lying on the seams.
SCG-3 & SCG-4 uses 3 inch diameter piping.
SCG-5 & SCG-6 uses 4 inch diameter piping.
SCG-7 thru SCG-9 uses 5 inch diameter piping.
10. Air intake termination must be located:
4. Install fire stops where vent passes through floors,
ceilings or framed walls. The fire stop must close
the opening between the vent pipe and the structure.
Vertical - At least twelve (12) inches above the roof
surface plus the expected snow accumulation.
11. Start at collar on burner enclosure (inside boiler
jacket) and work towards the air intake terminal.
5. Whenever possible, install vent straight through
the roof. Refer to Figure 7 if offset is necessary.
Maintain minimum clearance to combustible
materials.
12. Maintain minimum of ¼ inch per foot slope on
horizontal runs. Slope down towards boiler.
6. Install Vent Terminal.
13. The air intake pipe must be adequately supported
with straps or supports no less than five (5) feet
apart on horizontal runs. The complete air intake
piping system must be rigid and able to withstand
minor impacts without collapse.
a. Size roof opening to maintain minimum
clearance from combustible materials.
b. Extend vent pipe to maintain minimum vertical
and horizontal distance of twelve (12) inches
from roof surface. Allow additional vertical
distance for expected snow accumulation.
Provide brace as required. Refer to Figures 8A
and 8B.
14. Inlet air pipe penetration:
Vertical - Size roof opening to allow easy insertion
of inlet piping and allow proper installation of
flashing and storm collar.
a. Use appropriately designed vent flashing
when passing through roofs. Follow flashing
manufacturers’ instructions for installation
procedures. Flashing manufacturers are Air-
Jet, American Metal Products, Metal Fab, and
Simpson Dura-Vent.
NOTICE
Vertical venting requires the use of roof flashing
and a storm collar to prevent moisture from
entering the structure.
c. Install storm collar on vent pipe immediately
above flashing. Apply Dow Corning Silastic 732
RTV Sealant between vent pipe and storm collar
to provide weathertight seal.
b. Extend air intake pipe to maintain minimum
vertical and horizontal distance of twelve
(12) inches from roof surface. Allow
additional vertical distance for expected snow
accumulation. Provide brace as required. Refer
to Figures 8A and 8B.
d. Attach vent terminal.
Vertical Air Intake Piping –
c. Vertical air intake requires flashing and a storm
collar to prevent moisture from entering the
structure.
7. Do not exceed maximum air intake length. Refer to
Table 4.
17
d. Install storm collar on air intake pipe
immediately above flashing. Apply Dow
Corning Silastic 732 RTV Sealant between
air intake pipe and storm collar to provide
weathertight seal.
15. Seal all joints airtight, using silicone caulk or self-
adhesive aluminum tape.
16. Install Air Intake Terminal:
Vertical - Insert intake piping into intake terminal
collar. Secure terminal to intake piping and seal
joint with silicone caulk.
e. All exposed air intake piping must be
constructed of corrosion resistant material such
as aluminum, stainless steel or PVC.
18
19
ꢀ0
ꢀ1
Figure 9: Vertical Air Intake Piping
ꢀꢀ
F. Combination Horizontal Venting System –SCG-3 Through SCG-6 ONLY – See Figures 10 and 11.
1. Do not exceed maximum vent/air intake lengths.
Refer to Table 4.
NOTICE
This vent system requires components not
supplied with the boiler.
2. Install Combination Vent/Air Terminal. See Figure 11.
a. After determining the location with reference to Section B - General Venting Guidelines, cut a 6-1/8 inch square
opening in the wall for the air box sub-assembly which is 6 inch square.
b. Remove and save shipping screw from end panel with collar and vent pipe assembly. This will be reinstalled in a later
step.
Vent Carton Part Number 61106012 (Includes Items Below)
Description
Air Box Sub-Assembly (6” square x 2’ long)
Exterior Wall Cover (10” square)
Component Part Number
61106011
A
B
C
D
E
F
71106016
4” x 3” Vent Pipe Reducer
8116239
Plate-Seal Exterior Cover (2)
71106017
#8 x ½” Stainless Steel Sheet Metal Screw (19)
#10 - 32 x ¼” Stainless Steel Machine Screw (8)
#10 - 32 x ½” Aluminum Spacer (4)
80860047
80860842
G
80861617
COMBINATION hORIZONTAl VENT SySTEM COMPONENTS
ꢀꢁ
c. From exterior of building, insert air box sub-
assembly into square opening. Push air box
inward until wall flange is against wall, check
for level and mark the location of the four (4)
securing holes on the exterior wall. Remove air
box from wall.
3. Install Vent Piping. See Figures 10 and 11.
a. Start at vent connector on boiler, see Figure 43
on Page 72, and work towards combination vent/
air terminal.
b. Installation of a vertical vent tee 8116304U is
required on all vertical vent applications. See
Figures 12 and 13. Attach vertical vent drain
tee directly to elbow or horizontal pipe from an
elbow immediately after vent connector.
d. Drill four (4) pilot holes, properly sized for the
non-corrosive fasteners (stainless steel, brass, or
aluminum) to be used to secure the wall flange to
the exterior wall. (Securing screws not supplied
with kit.)
c. Slope horizontal runs minimum ¼ inch per foot.
Slope towards vertical vent drain tee. Position
weld seams in vent pipes, in all horizontal runs,
at the top to avoid condensate from lying on the
seams.
e. Attach four (4) 1/2 inch long threaded aluminum
spacers to the outer flanges of the exterior
wall flange with four (4) number 10 - 32 x 1/4
inch stainless steel machine screws provided.
(See Figure 11.)
d. Use 3/4 inch pipe strap to support horizontal runs
and maintain vent location and slope. Maximum
support spacing is five (5) feet.
f. Apply a 1/4 inch thick continuous bead of
silicone caulk to perimeter of exterior wall
flange’s back surface to provide a weathertight
seal.
e. Install vent piping to connect vent connector
on boiler and combination vent/air terminal.
Reference Section B - General Venting
Guidelines for proper procedure for joining pipe
and fittings.
g. Reinstall air box sub-assembly into opening in
exterior wall and secure to wall.
f. Connect vent piping to combination vent/air
terminal. See Figure 10.
WARNING
Non-corrosive fasteners must be used.
4. Install Air Intake Piping. See Figures 10 and 11.
a. Do not exceed air intake length. See Table 4.
h. Apply a bead of silicone caulk to perimeter of
wall flange, where the wall and flange join. Use
a tool or your finger and apply pressure while
smoothing caulking to provide a weathertight
seal.
b. Use single wall metal pipe or PVC and fittings
available at most heating distributors.
c. Air intake pipe diameter is based on boiler size.
SCG-3 & SCG-4 uses 3 inch diameter piping.
SCG-5 & SCG-6 uses 4 inch diameter piping.
SCG-7 thru SCG-9 uses 5 inch diameter piping.
i. From interior of building, insert end panel with
collar and vent pipe assembly into open end of
air box sub-assembly. (See Figure 11.)
d. Start at collar on burner enclosure (inside boiler
jacket) and work towards the combination vent/
air terminal.
j. Secure end panel to air box sub-assembly with
shipping screw and thirteen (13) number 8 sheet
metal screws provided.
e. Maintain minimum of 1/4 inch per foot slope on
horizontal runs. Slope down towards boiler.
k. From exterior of building, position 10 inch
square exterior wall cover over exterior wall
flange. Insert 3 inch diameter vent pipe into
center opening in terminal cover. Align four
(4) holes on cover with 1/2 inch long threaded
spacers on wall flange. Secure terminal cover
with four (4) number 10 - 32 x 1/4 inch stainless
steel machine screws provided.
f. The air intake pipe must be adequately supported
with straps or supports no less than five (5)
feet apart on horizontal runs. The complete air
intake piping system must be rigid and able to
withstand minor impacts without collapse.
g. Connect Air Intake Piping to Combination Vent/
Air Terminal. See Figure 10.
l. Apply a bead of silicone caulk to perimeter of
plate-seal and around pipe. Secure plate-seal to
exterior cover with six (6) #8 stainless steel sheet
metal screws provided. Smooth caulk around
plate-seal and pipe to provide weathertight seal.
NOTE: When installing 3 inch diameter air intake
piping for a SCG-3 or SCG-4 application, the use of
a 4 inch x 3 inch reducer will be required to connect
air intake piping to combination vent/air terminal.
(Reducer included with combination horizontal
venting kit).
m. Install Vent Terminal supplied with boiler to vent
pipe penetrating through terminal cover. Join
terminal and pipe with locking band and seal
with RTV (see Figure 3).
h. Seal all joints airtight, using silicone caulk or
self-adhesive aluminum tape.
ꢀ4
ꢀ5
ꢀꢂ
G. Combination Vertical Venting System – SCG-3 Through SCG-6 ONLY – See Figures 12, 13 and 14.
NOTICE
This vent system requires components not
supplied with the boiler.
Part Number
Description
SCG-3 & SCG-4
100222-01
SCG-5 & SCG-6
Vent Carton Part Number
Air Intake Tee
100223-01
100225-01
100224-01
Termination Adapter
100226-01
COMBINATION VERTICAl VENT SySTEM COMPONENTS
ꢀ7
1. Saf-T Vent SC is an advanced concentric vent
system designed for zero clearance installation
in residential applications. The inner wall is
constructed from superferritic AL29-4C® stainless
steel. The outer wall is also constructed from
stainless steel, providing durability and a lasting
finish.
the system in place. A continuous straight-line
pitch of at least ¼” (2°) to the foot on horizontal
runs must be maintained in order to properly rid
the system of the corrosive condensate.
5. General Installation Requirements:
•
Saf-T Vent SC vent sections, or other Saf-T
Vent products, must be used throughout the
entire length of the system. Alternatives such
as galvanized pipe, PVC, nonmetallic pipe,
prefabricated chimney, field-fabricated vents
or Type B vent sections must not be used. Do
not mix pipes, fittings, or joining methods from
different manufacturers.
2. As a Special Gas Vent system: Saf-T Vent is
approved for use on ANSI Category I, II, III, and
IV Gas-Burning Appliances and certain Direct Vent
Appliances. Saf-T Vent SC is appropriate for use on
appliances that specify an AL29-4C venting system.
3. As a Sealed Combustion system: The unique
concentric design of Saf-T Vent SC also allows it
to function as a pipe-in-a-pipe vent. Products of
combustion are exhausted out through the inner wall
while combustion air is drawn in through the outer
wall. An appliance can be direct-vented with only
a single penetration through the building structure.
This application must be approved by the
Appliance Manufacturer.
•
•
•
More than one appliance may not be
interconnected to any part of the venting system.
Any penetrations of ceilings, floors or walls must
be properly fire-stopped.
Whenever gas-burning equipment is installed in
the same space where halogenated substances
may exist (refrigerants, solvents, bleaches,
salts, etc.), clean outside air must be utilized for
combustion.
Note: Saf-T Vent SC includes an integral seal and
does not require RTV sealant. However, sealant
may be necessary when connecting Saf-T Vent SC
components directly to certain appliance flue collars
and to the gasket-less Saf-T Vent GC and Saf-T Vent
CI vent systems.
•
•
•
The vent system shall not be routed into,
through or within any other actively used vent or
chimney.
Seal weather exposed joints of the outer jacket
with foil tape or an exterior grade silicone
sealant.
For applications up to 550°F/288°C, approved
sealants include GE RTV 106 and Dow Corning
736.
Combustible Material is any material made of
or surfaced with wood, compressed paper, plant
fibers, or other materials that are capable of
being ignited or burned. Such material shall be
considered combustible even though it is flame-
proofed, fire-retardant, or plastered. (Source:
NFPA54/ANSI Z223.1-1999.)
For applications up to 300°F/149°C, approved
sealants include GE RTV 106 and Dow Corning
732.
4. Pre-Installation Considerations:
•
Proper planning prior to installation is essential
as to avoid possible contact with concealed
plumbing or electrical wiring inside walls,
floors or ceilings as well as maintaining proper
clearances. Be sure to plan a sufficient number
of supports for the entire system that will
•
Non-Combustible Material is any material that
is not capable of being ignited and burned, such
material consisting entirely of, or a combination
of, steel, iron, brick, tile, concrete, slate,
asbestos, glass and plaster. (Source: NFPA54/
ANSI Z223.1-1999.)
maintain the required straight-line pitch and hold
ClEARANCES TO COMBUSTIBlES:
Clearance to
Combustible
Maximum Flue
Gas Temp. (°F)
Diameter
Orientation
Enclosure
Material
Vertical, No
Offsets
550
0”
Fully enclosed by combustible material on all
330
400
400
550
550
sides
Horizontal,
Vertical with
Offsets
1”
0”
1”
0”
3” - 4”
Unenclosed, at least 1 side open, combustible
material on a maximum of 3 sides
Any
Noncombustible material
ꢀ8
•
For a venting system that extends through
any zone above that on which the connected
appliance is located (except for one and two
family dwellings), the vent system shall be
enclosed with an enclosure having a fire
resistance rating equal to or greater than that of
the floor or roof assemblies through which it
passes.
6. Vertical Installation Requirements:
a. Seal weather exposed joints of the outer jacket
with foil tape or an exterior grade silicone
sealant.
b. The vent system must terminate at least 3 feet
above the roof line and at least 2 feet higher than
any portion of the building within 10 feet.
c. When terminated at a height of more than 6 feet
the stack must be supported by a support bracing.
The vent should be supported every 10 feet.
•
•
Design any enclosure to permit inspection of the
system.
Do not place any type of insulation in any
required clearance spaces surrounding the vent
system.
d. The total continuous distance of the vent system
from the appliance flue collar to the termination
shall not exceed that specified in the appliance
manufacturer’s installation instructions.
e. In cold climates do not install a condensate drain
on the exterior of the building. Doing so may
result in dangerous icy conditions on surfaces
near the drain and may cause damage to the vent
system and/or the building exterior.
f. Install supports every 10 feet vertically along the
vent pipe route. Vertical supports are required
after every transition to vertical and are required
after every offset elbow. When the vent is free
standing and penetrates a roof/ceiling another
means of support must be used at a second
location. Refer to the Vertical Supports section
in this manual.
ꢀ9
7. Joint Assembly Instructions:
a. Before joining the sections or fittings together, use an alcohol pad to wipe the joint area of both ends of the inner
pipe. This will remove any foreign matter which may affect the integrity of the seal. Install the system with the
female ends (ends with the red seal) pointing away from the appliance. (Unless specified differently by the appliance
manufacturer.)
b. Insert the male end of the inner pipe into the female end of the previous section. In extremely dry conditions it may be
helpful to moisten the seal with clean water prior to assembly. Push firmly until the outer jacket has made contact with
the snap ring located inside the female end of the previous section. When fully assembled the outer female end will
overlap the male end 1”.
c. Use the three (3) self-tapping screws provided to connect the outer vents. No pre-drilling is required.
NOTICE
Do not overtighten. If using a variable torque drill, use a low torque setting to install screws, as not to strip
out the holes. If a hole becomes stripped due to overtightening, a larger diameter screw (½” long max.) or
short pot rivet can be used.
ꢁ0
8. Straight Sections Cut To Length:
e. Add 3” to the distance measured previously for the
cut length of the inner vent pipe. Mark a cut line on
the inner vent on the male end (the end without the
red seal).
If a custom length of SC is necessary, a standard vent
section can be cut.
a. Measure the distance of the length needed, taking the
measurement from the end of one of the outer jackets
to the beginning of the other outer jacket on the
section to connect to, (A to B on diagram).
The inner pipe is always cut 1” longer than the
outer pipe.
f. WEAR GLOVES, as cut ends are very sharp. Cut
the pipes with an abrasive cutoff saw, plasma cutter,
or compound snips. If using snips, start the cut at
the male end and follow a spiral path around the pipe
until the cutoff mark is reached. File off any burrs
or rough edges that develop in the cutting process
and clean off any dust or grit. If the cutting process
distorts the roundness of the pipes, carefully use your
thumbs to re-round the ends.
b. Select a section that is longer than the required
length.
c. It will be necessary to disassemble the vent prior to
cutting.
Stand the section on end with the holes up. Find the
end of snap ring and pry it out of its groove, being
careful not to damage the ends of the vent pipes.
Pull up on end of the snap ring and pull it out from
the end of the pipe. It may want to spiral out as it is
removed. After the snap ring is removed, the inner
vent pipe can be separated from the outer jacket.
g. Reassemble the inner vent into the outer jacket and
reinstall the snap ring into the groove. Push the
inner vent into the outer jacket until the triangle on
the inner vent is seated firmly against the bead on
outer jacket. Start one end of the snap ring into the
groove of the outer pipe. Slowly turn and feet the
snap ring into the groove in a spiral motion, and
continue around the pipe until the snap ring is fully
inserted. Ensure that the triangle on the inner vent is
all the way down against the bead of the outer jacket
by pushing in firmly. Also ensure that the snap ring
is completely in the groove all the way around outer
jacket.
d. Add 2” to the distance measured previously for the
cut length of the outer jacket. Mark a cut line on the
outer jacket on the male end (the end without holes in
it).
An effective way of marking is to run a length of tape
around the section, assuring a square cut.
ꢁ1
9. Air Intake Connections for Direct Vent and Sealed
Combustion Appliances*:
The Air Intake Tee may be used on approved direct vent
and sealed combustion appliances that have separate (non-
concentric) air intake and flue exhaust collars. The male end
of the tee connects to EZ Seal appliance adapters and the tee
takeoff/snout connects to the appliance air intake.
•
•
•
Insert the male end of the Air Intake Tee into the female
end of the EZ Seal vent section or appliance adapter and
complete the ring and tab connection.
Insert the male end of the next SC section into the
female end of the Air Intake Tee and secure as described
elsewhere in this manual.
Connect the tee takeoff to the appliance combustion air
inlet using appropriate hose or pipe.
* Direct Vent Appliances are constructed and installed so that
all air for combustion is supplied directly from the outside
atmosphere. The passage for the combustion air is allowed
a small amount of leakage in the building environment. No
special installation considerations are required to use Saf-T
Vent SC on Direct Vent appliances unless specified by the
appliance manufacturer. Sealed Combustion appliances are
similar to Direct Vent except the combustion air passage must
be sealed to prevent leakage within the building envelope.
When Saf-T Vent SC is used on approved Sealed Combustion
appliances the joints of the outer jacket must be sealed with
a foil tape (example: 3M 425), or approved silicone sealant
(example: Dow Corning 732).
10. Condensate Drains:
When An Internal Condensate Drain is NOT Part of the
Appliance:
•
A Saf-T Vent SC In-Line Drain Section is strongly
recommended. Install this drain fitting as close to the
appliance flue collar as possible.
•
A condensate drain is required for every 30 feet of
horizontal vent and at/near the bottom of a vertical stack.
•
Use the In-Line Drain Section for a straight horizontal or
vertical run. When used horizontally, rotate the fitting so that
the drain tube is as vertical as possible.
•
A Condensate Drain Tube Kit is available to direct the condensate
to an appropriate location, i.e. floor drain or vented sanitary
sewer connection. A trap loop must be formed into the drain
hose and must be a diameter that is at least four (4) times the
appliance’s rated stack pressure in inches of water column or 3
inches, whichever is greater. Secure the loop with a cable tie.
Prior to final assembly the trap loop must be ‘primed’ by pouring
a small quantity of water into the drain hose. Inspect at least
annually to verify the trap is ‘primed’.
•
•
Follow all local and national codes and regulations for the
draining of acidic condensate.
In cold climates do not install a condensate drain on the exterior
of the building. Doing so may result in dangerous icy conditions
on surfaces near the drain and may cause damage to the vent
system and/or the building exterior.
ꢁꢀ
11. Horizontal Supports:
Saf-T Vent SC must have supports for every six (6) feet of horizontal run and after every transition from vertical to
horizontal. Support hangers by themselves do not maintain the necessary clearances to combustible materials; be sure to
consider clearances when planning the system.
The supports must be secured to solid material using at least #10 fasteners. Do not fasten supports to drywall sheathing
without using hollow wall anchors. The conduit supports must maintain the ¼” per foot pitch to avoid collection of
condensate in the vent. Position the vent so that the welded seam is on the top.
0” Clearance Support Clamp, (SC_ _SUP): Attach the bracket to the structure but do not tighten in place. Open the
hose clamp and slip it under the support bracket. Position the clamp between the mounting screws and rotate the clamp
so that the screw housing will be accessible after the vent is installed. Restart the threads on the hose clamp and securely
tighten the mounting screws to the structure. This can also be installed vertically.
1” Clearance Support Clamp, (SC_ _SUP1): Supports the vent at 1” clearance to the structure. Line up the support
mounting brackets so that the mounting screws will follow the center line of the vent section. This can also be installed
vertically.
ꢁꢁ
Support Clamp, (4_ _27SS): Support clamps are sold in pairs and can be clamped around the vent and suspended from a
rod or cable. They can be used singularly as a saddle clamp to rest the vent in and suspended from two (2) rods or cables.
Support Legs Rotated Horizontally: Support legs can be used on horizontal runs by rotating the clamp at the rivet
connection. The legs can be cut to shorter lengths if necessary.
Vertical Supports, (SC_ _VSL): Vertical support legs can be used above or below a structure for support. To install,
slide the support clamp over the end of the vent section, leaving the clamp loose. Position the support legs and install
two (2) screws through each leg into the structure. Tighten the clamp around vent pipe. The legs can be cut to shorter
lengths if necessary and can rotate around the support clamp at the rivet connection. By rotating the clamp to a horizontal
position the support legs can be used on horizontal runs.
ꢁ4
Fire Stop/Wall Thimble/Support, (SC_ _FS):
•The Saf-T Vent SC Fire Stop can be used as a firestop, a wall thimble, or as a support plate.
•To use as a Wall Thimble prepare an opening according to the chart below. Remove any insulation from the opening,
using additional framing if necessary. Attach the plate over the center of the opening using appropriate fasteners.
•Install the vent section through the thimble plate and secure the section to the thimble by screwing the self-tapping
screws through the holes in the tabs on the plate and into the outer wall of the vent. Apply silicone sealant around the vent
section where it passes through the plate and around the plate where it is attached to the structure.
•To use as a Firestop before passing through ceilings or enclosed chases, prepare a round or square opening ¼” larger than
the outer jacket (5¼” for 3” vent or 7¼” for 4” vent). Remove any insulation from the opening. Secure the firestop to
the structure at the four (4) corners. Install the vent section through the firestop and secure to the thimble by screwing the
self-tapping screws through the holes in the tabs on plate and into outer wall of the vent. This method can also be used to
support the vent section either vertically or horizontally.
Tall Cone Flashing:
Directly On Roof or Curb:
Tall Cones are available for flat (SC_ _TCF), 2/12 pitch (SC_ _TCFA), and 6/12 - 12/12 pitch roofs (SC_ _TCFB).
Prepare a square or round opening at least 1/4” larger than the outer jacket (5¼” for 3” vent or 7¼” for 4” vent). Remove
any insulation from the opening. Apply weather-stripping or outdoor caulk to the bottom of the cone plate and attach the
plate to the roof using common construction methods. Flash over the cone plate and seal the fastener heads using normal
roofing requirements. When the vent pipe is in place through the Tall Cone, attach a storm collar (sold separately) around
the pipe. Apply high temperature silicone sealant around the pipe where it passes through the top of the storm collar.
Continue to install vent sections as needed to meet the height requirements by code. Seal weather exposed joints of the
outer jacket with foil tape or an exterior grade silicone sealant.
ꢁ5
Vertical Terminations, (SC_ _VT): Install the vertical termination adapter into the last vent section and secure with the
three (3) self-tapping screws provided. If the exhaust termination needs to be extended, a section of EZ Seal vent can be
connected directly to the vertical termination adapter. Seal weather exposed joints of the outer jacket with foil tape or
an exterior grade silicone sealant. To allow for inspection of the system, do not seal the exhaust termination.
ꢁꢂ
H. Indoor Air Installation – See Figures 12, 13, 14, 15 and 16.
1. Do not exceed maximum vent length. Refer to
Table 4.
11. Install fire stops where vent passes through floors,
ceilings or framed walls. The fire stop must close
the opening between the vent pipe and the structure.
Fire stop manufacturers are Air-Jet, American Metal
Products, Metal-Fab, and Simpson Dura-Vent.
Horizontal –
2. Maintain minimum ¼ inch per foot slope in
horizontal runs. Position weld seams in vent pipes,
in all horizontal runs, at the top to avoid condensate
from lying on the seams.
12. Whenever possible install vent straight through roof.
Refer to Figure 6. Maintain minimum clearance to
combustible materials. For attic offset see Figure 7.
3 Recommended horizontal installation consists of
vent being sloped down away from boiler. See
Figure 12.
13. Install Vent Terminal.
a. Size roof opening to maintain minimum
clearance from combustible materials.
4. Alternate horizontal installation consists of vent
being sloped down toward the boiler. A horizontal
vent tee is required. See Figure 13.
b. Use appropriately designed vent flashing
when passing through roofs. Follow flashing
manufacturers’ instructions for installation
procedures. Flashing manufacturers are Air-
Jet, American Metal Products, Metal Fab, and
Simpson Dura-Vent.
5. Use appropriately designed thimbles when passing
through combustible walls (thimble use optional
for noncombustible walls). Insert thimble through
wall from outside. Secure outside flange to wall
with nails or screws, and seal with sealant material.
Install inside flange to inside wall, secure with nails
or screws, and seal with sealant material.
c. Extend vent pipe to maintain minimum vertical
and horizontal distance of twelve (12) inches
from roof surface. Allow additional vertical
distance for expected snow accumulation.
Provide brace as required. Refer to Figure 15.
6. For noncombustible wall application when thimble
is not used, size opening such that female (bell) end
with locking band attached cannot pass through.
d. Vertical venting requires flashing and a storm
collar to prevent moisture from entering the
structure.
7. Join vent terminal to vent pipe. Locate vent
terminal between seventeen (17) inches and twenty-
nine (29) inches from wall when joined to inside
vent piping. See Figure 14.
e. Install storm collar on vent pipe immediately
above flashing. Apply Dow Corning Silastic 732
RTV Sealant between vent pipe and storm collar
to provide weathertight seal.
8. Insert vent pipe through thimble/opening from
outside and join to vent system. Apply sealant
between vent pipe and opening/thimble to provide
weathertight seal.
f. Attach vent terminal.
Vent Terminal and Air Intake Terminal –
14. Join vent terminal to 45° elbow (supplied by
installer). Join 45° elbow/terminal assembly to vent
pipe. Refer to Section C for proper procedures for
joining vent pipe and fittings. See Figure 3.
Vertical –
10. Installation of a vertical vent drain tee is required
on all vertical vent applications. See Figure 6.
Attach vertical vent drain tee directly to elbow or
horizontal pipe from an elbow immediately after
vent connector.
15. Install supplied air intake terminal. See Figure 16.
ꢁ7
ꢁ8
ꢁ9
Figure 14: Optional Indoor Air - Vent Terminal Installation
Figure 15: Indoor Air - Vertical Vent Terminal Installation
Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“y”) distance of twelve
(1ꢀ) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.
Figure 1ꢂ: Indoor Air - Air Intake Terminal Installation
40
I. Optional Exterior Separate Horizontal Vent/Air Intake Terminal Mounting – See Figures 17, 18, 19, 20, 21 and 22.
d. At top of vent pipe length install an AL 29-4C®
90° elbow so that elbow leg is opposite the
building’s exterior surface.
1. Do not exceed maximum vent/air intake lengths.
Refer to Table 4.
2. This installation will allow a maximum of seven (7)
feet vertical exterior run of the vent/air intake piping
to be installed on separate horizontal venting and
indoor air horizontal venting.
e. If installation requires indoor air, install
AL 29-4C® 45° elbow to upper AL 29-4C® 90°
elbow so that leg of 45° is in down direction (see
Figure 21 or 22). If not using indoor air, proceed
to Step f.
NOTICE
f. Install horizontal vent terminal (provided with
boiler).
Exterior run to be included in equivalent vent/air
intake lengths.
g. Brace piping if required.
3. Install vent piping.
4. Air Intake Piping (not required for indoor air).
a. Install vent piping for desired venting system.
Refer to specific section for details for vent pipe
installation.
a. Install air intake piping for desired venting
system. Refer to specific section for details for
air intake installation.
b. After penetrating wall/thimble, install an
AL 29-4C® 90° elbow so that elbow leg is in the
up direction.
c. Install maximum of seven (7) feet of AL 29-4C®
vent pipe. Refer to Sections C through E for proper
procedures for joining vent pipe and fittings.
b. After penetrating wall, install a corrosion
resistant 90o elbow so that elbow leg is in the up
direction.
c. Install maximum of seven (7) feet of corrosion
resistant air intake pipe.
d. At top of air intake pipe install air intake
terminal (provided with boiler).
e. Brace piping if required.
Figure 17: Optional Separate horizontal Air ꢁ” or 4” Intake Terminal Installation
41
Figure 18: Optional Separate horizontal Air 5” Intake Terminal Installation
Figure 19: Optional Separate horizontal ꢁ” Vent Terminal Installation
4ꢀ
Figure ꢀ0: Optional Separate horizontal 4” Vent Terminal Installation
Figure ꢀ1: Optional Separate horizontal ꢁ” Vent Terminal Installation (Indoor Air)
4ꢁ
Figure ꢀꢀ: Optional Separate horizontal 4” Vent Terminal Installation (Indoor Air)
44
IV. Water Piping and Trim
WARNING
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and
can lead to boiler failure. Burnham’s Standard Warranty does not cover problems caused by oxygen
contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
Where
A. Design and install boiler and system piping to
prevent oxygen contamination of boiler water and
frequent water additions.
The universal location for a LWCO on both gas and oil
hot water boilers is above the boiler, in either the supply
or return piping. The minimum safe water level of a
water boiler is at the uppermost top of the boiler; that is,
it must be full of water to operate safely.
1. There are many possible causes of oxygen
contamination such as:
a. Addition of excessive make-up water as a result
of system leaks.
What Kind
b. Absorption through open tanks and fittings.
c. Oxygen permeable materials in the distribution
system.
The SCG boiler is designed to accept the wiring of the
Safgard Model 1100-H4 (P/N 100592-01) LWCO. This
is a probe type LWCO. The factory wiring is designed
to allow simple “Plug-in” installation of the wiring.
2. In order to insure long product life, oxygen sources
must be eliminated. This can be accomplished by
taking the following measures:
How to Pipe
A “tee” is commonly used to connect the probe LWCO
to the supply or return piping, as shown below.
a. Repairing system leaks to eliminate the need for
addition of make-up water.
b. Eliminating open tanks from the system.
c. Eliminating and/or repairing fittings which allow
oxygen absorption.
d. Use of non-permeable materials in the
distribution system.
e. Isolating the boiler from the system water by
installing a heat exchanger.
f. Use properly designed and operating air
elimination devices in water piping.
B. Low Water Cut Off (LWCO) on Hot Water Boilers
(Optional)
WARNING
lWCO location
DO NOT ATTEMPT to cut factory wires to
install an aftermarket low Water Cut Off
(LWCO). Only use connections specifically
identified for Low Water Cut Off.
Select the appropriate size tee using the LWCO
manufacturer’s instructions. Often, the branch
connection must have a minimum diameter to prevent
bridging between the probe and the tee. Also, the run
of the tee must have a minimum diameter to prevent
the end of the probe from touching or being located too
close to the inside wall of the run of the tee.
In all cases, follow the low Water Cut Off
(lWCO) manufacturer’s instructions.
When
A low water cutoff is required to protect a hot water
boiler when any connected heat distributor (radiation)
is installed below the top of the hot water boiler (i.e.
baseboard on the same floor level as the boiler). In
addition, some jurisdictions require the use of a LWCO
with a hot water boiler.
Ideally, manual shutoff valves should be located
above the LWCO and the boiler to allow for servicing.
This will allow probe removal for inspection without
draining the heating system. Many probe LWCO
manufacturers recommend an annual inspection of the
probe.
45
How to Wire
Ensure power is turned off to boiler.
Locate the LWCO jumper wire in the factory wiring
harness. Remove the jumper wire and install
the LWCO wiring from LWCO Model 1100-H4
(P/N 100592-01) into the plug of the SCG factory
wiring.
WARNING
Pressure relief valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut-off
valves, plugs or caps. Consult local Codes for
proper discharge piping arrangement.
How to Test
Shut off fuel supply. Lower water level until water
level is BELOW the LWCO. Generate a boiler demand
by turning up thermostat. Boiler should not attempt to
operate. Increase the water level by filling the system.
The boiler should attempt to operate once the water
level is above the LWCO.
F. Space heating and domestic water heating with
Alliance™ water heater. Install Alliance water heater as
a separate heating zone. Refer to Alliance Installation,
Operating and Service Instructions for additional
information.
G. If boiler is used in connection with refrigeration
systems, boiler must be installed with chilled medium
piped in parallel with the heating boiler using
appropriate valves to prevent chilled medium from
entering boiler, see Figure 23.
NOTICE
Ensure the location of the lWCO in the piping will
allow for connection of the lWCO wiring harness
to the factory wiring of the SCG.
C. Connect system supply and return piping to boiler.
See Figures 25 and 26. Maintain minimum ½ inch
clearance from hot water piping to combustible
materials.
NOTICE
Burnham recommends sizing the system
circulator to supply sufficient flow (GPM) to allow a
ꢀ0°F temperature differential in the system. When
sizing the system circulator, the pressure drop of
all radiators, baseboard and radiant tubing and all
connecting piping must be considered.
D. Install circulator with flanges, gaskets and bolts
provided. Circulator harness allows circulator to be
mounted on supply or return. Connect harness to
circulator and secure any excess conduit.
Figure ꢀꢁ: Recommended Piping for Combination
heating & Cooling (Refrigeration) System
H. If boiler is connected to heating coils located in
air handling units where they may be exposed to
refrigerated air, boiler piping must be equipped with
flow control valves to prevent gravity circulation of
boiler water during operation of cooling system.
E. Install supply manifold, pressure/temperature gauge
and pressure relief valve.
See Figure 24. Pressure Relief Valve must be installed
with spindle in vertical position. Installation of the
relief valve must comply with the ASME Boiler and
Pressure Vessel Code, Section IV.
I. Use a boiler bypass if the boiler is to be operated
in a system which has a large volume or excessive
radiation where low boiler water temperatures may be
encountered (i.e. converted gravity circulation system,
etc.).
4ꢂ
Figure ꢀ4: Supply Water Manifold Piping
Install pipe tee between circulator and boiler return
L. Oil, grease, and other foreign materials which
accumulate in new hot water boilers and a new
or reworked system should be boiled out, and
then thoroughly flushed. A local qualified water
treatment chemical specialist is a suggested source
for recommendations regarding appropriate chemical
compounds and concentrations which are compatible
with local environmental regulations.
along with second tee in supply piping as shown in
Figure 25 or 26. Bypass should be same size as the
supply and return lines with valves located in bypass
and supply outlet as illustrated in Figure 25 or 26 in
order to regulate water flow to maintain higher boiler
water temperatures.
After the boiler is operational (reference Section VIII.
System Start-Up) set by-pass and boiler supply valves
to half throttle position to start. Operate boiler until
system water temperature reaches normal operating
range.
M. After the boiler and system have been cleaned and
flushed, and before refilling the entire system add
appropriate water treatment chemicals, if necessary, to
bring the pH between 7 and 11.
Adjust valves to provide 180° to 200°F supply water
temperature. Opening the boiler supply valve will raise
system temperature, while opening the by-pass valve
will lower system supply temperature.
N. If it is required to perform a long term pressure
test of the hydronic system, the boiler should first be
isolated to avoid a pressure loss due to the escape of air
trapped in the boiler.
J. A hot water boiler installed above radiation level
must be provided with a low water cutoff device as part
of installation.
To perform a long term pressure test including the
boiler, ALL trapped air must first be removed from the
boiler.
K. If a low water cutoff is required, it must be mounted
in the system piping above the boiler. The minimum
safe water level of a hot water boiler is just above the
highest water containing cavity of the boiler; that is, a
hot water boiler must be full of water to operate safely.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler contained
trapped air.
47
48
49
V. Gas Piping
WARNING
3. Length of piping and number of fittings. Refer to
Table 7 for maximum capacity of Schedule 40 pipe.
Table 8 lists equivalent pipe length for standard
fittings.
Failure to properly pipe gas supply to boiler may
result in improper operation and damage to the
boiler or structure. Always assure gas piping is
absolutely leak free and of the proper size and
type for the connected load.
4. Corrections for the specific gravity of natural gas
can be found in Table 6.
For materials or conditions other than those listed
above, refer to National Fuel Gas Code, NFPA54/ANSI
Z223.1, or size system using standard engineering
methods acceptable to authority having jurisdiction.
An additional gas pressure regulator may be
needed. Consult gas supplier.
A. Size gas piping. Design system to provide adequate gas
TABlE ꢂ: SPECIFIC GRAVITy CORRECTION
supply to boiler. Consider these factors:
FACTORS FOR NATURAl GAS
1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.
Minimum gas valve inlet pressure is stamped on
the rating label located in the boiler’s vestibule
compartment.
Specific
Gravity
Correction
Factor
Specific
Gravity
Correction
Factor
---
---
0.85
0.90
1.00
1.10
1.20
1.30
1.40
0.81
0.82
0.78
0.74
0.71
0.68
0.66
---
---
0.60
0.65
0.70
0.75
0.80
1.00
0.96
0.93
0.90
0.87
2. Maximum gas demand. Refer to the boiler’s input
as printed on it’s rating label. Also consider existing
and expected future gas utilization equipment (i.e.
water heater, cooking equipment).
TABlE 5: GAS RATINGS
Boiler
Model
Number Gas Pressure
Natural/LP
Maximum
Minimum Natural
Gas Pressure
(in. w.c.)
Minimum LP
Gas Pressure
(in. w.c.)
Natural
LP
Manifold
Pressure
(in. w.c.)
Manifold
Pressure
(in. w.c.)
(in. w.c.)
Inlet to Gas Valve Inlet to Gas Valve
SCG-3
SCG-4
SCG-5
SCG-6
SCG-7
SCG-8
SCG-9
14
4.5
11.5
3.5
10.5
NOTICE
SCG boilers built for altitudes greater than 4,999 feet above sea level need to be specially orificed to adjust for
changes in atmospheric conditions. The SCG boiler “H” Model has been certified to operate in atmospheric
conditions from 5,000 to 10,000 feet above sea level. Input is de-rated by 10% for applications at 5,000 feet
above sea level, and ꢀ0% for applications at 10,000 feet above sea levels. De-rate is based on ꢀ% reduction
per 1000 feet.
The SCG boiler is available in two (ꢀ) altitude Models: The “S” Model 0 to 4,999 feet above sea level, and the
“h” Model 5,000 to 10,000 feet above sea level.
For applications above 10,000 feet, consult the manufacturer.
50
TABlE 7: MAXIMUM CAPACITy OF SChEDUlE 40 PIPE IN CFh* FOR NATURAl GAS PRESSURES
OF 0.5 PSIG OR lESS
0.3 Inch w.c. Pressure Drop
0.5 Inch w.c. Pressure Drop
Length
[Feet]
½
132
92
73
63
56
50
46
43
40
38
¾
278
190
152
130
115
105
96
1
1¼
1,050
730
590
500
440
400
370
350
320
305
½
175
120
97
¾
1
1¼
1,400
950
770
660
580
530
490
460
430
400
10
20
30
40
50
60
70
80
90
100
520
350
285
245
215
195
180
170
160
150
360
250
200
170
151
138
125
118
110
103
680
465
375
320
285
260
240
220
205
195
82
73
66
61
90
57
84
53
79
50
* 1 CFH of Natural Gas is approximately equal to 1 MBH; 1 CFH of LP is approximately equal to 2.5 MBH; con-
tact your gas supplier for the actual heating value of your gas.
B. Connect boiler gas valve to gas supply system.
WARNING
Failure to use proper thread compounds on all
gas connectors may result in leaks of flammable
gas.
WARNING
Gas supply to boiler and system must be
absolutely shut off prior to installing or servicing
boiler gas piping.
1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liquefied petroleum gas.
3. Install sediment trap, ground-joint union and manual
shut-off valve upstream of boiler gas control valve
and outside jacket. See Figure 27.
Figure ꢀ7: Recommended Gas Piping
TABlE 8: EqUIVAlENT lENGThS OF STANDARD PIPE FITTINGS & VAlVES
VALVES FULLY OPEN
Pipe
Size
I.D.
Inches
Swing
Check
90°
Elbow
45°
90° Tee, Flow
90° Tee, Flow
Through Branch
Gate
Globe
Angle
Elbow Through Run
½”
¾”
06.22
0.824
1.049
1.380
0.35
0.44
0.56
0.74
18.6
23.1
29.4
38.6
9.3
4.3
5.3
6.8
8.9
1.6
2.1
2.6
3.5
0.78
0.97
1.23
1.60
1.0
1.4
1.8
2.3
3.1
4.1
5.3
6.9
11.5
14.7
19.3
1”
1¼”
51
4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, NFPA 70.
piping by closing boiler’s individual manual shutoff
valve.
2. Locate leaks using approved combustible gas
detector, soap and water, or similar nonflammable
solution.
C. Pressure test. The boiler and its gas connection must
DANGER
be leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over
½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at ½ psig or less, isolate boiler from gas supply
Do not use matches, candles, open flames or
other ignition source to check for leaks.
5ꢀ
VI. Electrical
DANGER
Positively assure all electrical connections are unpowered before attempting installation or service of
electrical components or connections of the boiler or building. lock out all electrical boxes with padlock
once power is turned off.
WARNING
Failure to properly wire electrical connections to the boiler may result in serious physical harm.
Electrical power may be from more than one source. Make sure all power is off before attempting any
electrical work.
Each boiler must be protected with a properly sized over-current device.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with
a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls
used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.
service switch such that the boiler can be shut-off
without exposing personnel to danger in the event of
an emergency. Connect the main power supply and
ground to the three (3) boiler wires (black, white and
green) located in the junction box at the inside top of
the boiler jacket. If a low water cutoff is to be used,
connect the low water cutoff so that all 120V power
to boiler is interrupted if the low water cutoff’s switch
opens.
A. General. Install wiring and electrically ground boiler
in accordance with authority having jurisdiction or, in
the absence of such requirements, follow the National
Electrical Code, NFPA 70, and/or CSA C22.1 Electrical
Code.
B. A separate electrical circuit must be run from
the main electrical service with an over-current
device/disconnect in the circuit. A service switch is
recommended and may be required by some local
jurisdictions. Install the service switch in the line
voltage “Hot” leg of the power supply. Locate the
C. Refer to Figures 28 and 29 for details on the internal
boiler wiring.
NOTICE
This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler.
This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the
limit control. Certain Local Codes require an additional water temperature limit. In addition, certain types
of systems may operate at temperatures below the minimum set point of the limit contained in the boiler.
If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat) located in the system
piping as shown in the Water Piping and Trim Section of this manual. Wire as indicated in the Electrical
Section of this manual.
NOTICE
All wire, wire nuts, controls etc. are installer supplied unless otherwise noted.
5ꢁ
54
NOTICE
If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing
below.
Figure ꢀ9: Internal Boiler Wiring ladder Diagram
55
D. System Controls and Wiring
1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.
2. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes.
3. Use armored cable (BX) over all exposed line voltage wiring.
4. If an Alliance™ indirect water heater is used, use priority zoning except for Hydro-Air Systems.
5. Single Zone Heating System – Refer to Figure 30 of this manual for the electrical diagram for this type of system.
Set the thermostat heat anticipator to 0.60 amps.
6. Single Zone Heating System with Alliance™ Water Heater - Refer to Figure 31 of this manual for the electrical diagram
for this type of system.
Set the thermostat heat anticipator to 0.60 amps.
7. Conventional Circulator Zoned System – Refer to Figure 32 of this manual for the electrical diagram for this type of
system.
Read, understand and follow all of the instructions provided with the Honeywell R8888 control.
Connect the thermostat of each zone and the circulator for that zone to R8888 panel. If an Alliance™ indirect water
heater is used, connect the Alliance™ thermostat and circulator to the Zone 1 terminals of the R8888.
Set the thermostat heat anticipator to 0.12 amps.
NOTICE
The honeywell R8888 Control is available in a three (ꢁ) zone Model (R8888A) and a four (4) zone Model
(R8888B). Up to four (4) R8888’s may be used together to provide control for up to twelve (1ꢀ) individual
zones. Only one (1) zone, the first zone of the main control, will provide priority circulation. If more than
four (4) zones are required, connect additional R8888’s by wiring the A, B, and C terminals of each control
together. Each R8888 requires a 120 volt power supply. If more than one (1) R8888 is used, set the panel
type switch to “main” on the first R8888 and set the panel type switch to “expansion” on the second, third
or fourth R8888.
8. Conventional Zone Valve Zoned System – Refer to Figure 33. Wiring to the most popular models of zone valves is given
in Figure 34.
Connect the thermostat of each zone and the zone valve for that zone to the R8889 control. If an Alliance™ indirect water
heater is used, connect the Alliance™ thermostat and zone valve to the “zone 1” terminals of the R8889.
Set the thermostat heat anticipator to 0.12 amps.
NOTICE
The honeywell R8889 Control is available in two three (ꢁ) zone models and two four (4) zone models.
Burnham recommends using Model R8889A for three (ꢁ) zone systems and Model R8889B for four (4) zone
systems. Models R8889C and R8889D have less load capacity and may not operate with certain types of
zone valves. Up to four (4) R8889’s may be used together to provide up to sixteen (1ꢂ) individual zones.
Only one (1) zone, the first zone of the main control will provide priority zoning for the Alliance indirect
water heater. If more than four (4) zones are required, connect additional R8889’s by wiring the A, B and
C terminals of each control together. Each R8889 requires a 120 volt power supply. If more than one (1)
R8889 is used, set the panel type switch to “main” on the first R8889 and set the panel type switch to
“expansion” on the second, third or fourth R8889.
5ꢂ
57
NOTICE
If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing
below.
58
59
ꢂ0
Figure ꢁ4: Different Manufacturer’s Zone Valve Connections to honeywell R8889
ꢂ1
VII. Modular Installation
inlet (or visa versa) if installation conditions do not
allow alternate arrangement.
A. General Guidelines
1. Read and follow all venting, combustion air,
water piping, gas piping and electrical instructions
contained in this manual unless otherwise instructed
in this section.
TABlE 9: MODUlAR BOIlER WATER
MANIFOlD SIZING
2. Consult Local Building Codes or National Fuel Gas
Code, NFPA 54/ANSI Z222.3 for restrictions and
instructions on modular boiler installations.
Recommended Minimum
Combined Output
Common Water Manifold
(MBH)
Size (NPT)
B. Module Sizing
< 166
< 260
< 550
< 900
< 2000
1¼”
1½”
2”
Burnham recommends sizing each boiler in a modular
system to provide 20 % of the combined heating load
where ever possible.
2½”
3”
C. Venting
1. Each boiler must have an individual vent pipe.
Refer to Venting Section of this manual for venting
guidelines and options.
E. Water Piping (See Table 9)
Installing a low water cutoff in the system piping of
modular systems is strongly recommended and may be
required by Local Codes.
WARNING
Do not manifold vent pipes together.
F. Gas Piping
1. Refer to National Fuel Gas Code, Local Codes and
Tables 7 and 8 for gas pipe sizing.
2. The maximum vent length for each boiler is fifty
(50) equivalent feet.
2. Each boiler must be piped as shown in Figure 27.
3. The minimum horizontal distance between vent
terminations is one (1) foot. Additional horizontal
distance is desirable to avoid frost damage to the
building. Vent terminations must be at least twelve
(12) inches above the ground plus the expected
snow accumulation.
WARNING
If gas pressure in the building is above ½ psig,
an additional gas pressure regulator is required.
Using one additional regulator for multiple
boilers may result in unsafe boiler operation.
The additional regulator must be able to properly
regulate gas pressure at the input of the smallest
boiler. If the regulator cannot do this, two or
more additional regulators are required. Consult
regulator manufacturer and/or local gas supplier
for instructions and equipment ratings.
CAUTION
Installing multiple vent terminations close
together promotes frost buildup on buildings. To
minimize this possibility, extend the distance from
the building to the end of the vent termination
and increase the horizontal distance between
terminations.
G. Electrical
4. Multiple vertical vent pipes may be piped through
a common conduit or chase so that one roof
penetration may be made. Each vent termination
must be one (1) foot from other terminations.
1. Each boiler must be provided with a fused
disconnect and service switch.
2. Install wiring in accordance with requirements of
authority having jurisdiction. In the absence of such
requirements, follow the National Electric Code,
NFPA 70 and/or CSA C22.1 Electric Code.
D. Air Intake Piping
1. Each boiler must have an individual air intake pipe,
refer to Venting Section of this manual for Air Intake
Guidelines and Options.
H. Modular Boiler Control Systems
Contact a controls manufacturer such as Honeywell or
Tekmar to properly apply a modular control system.
2. The maximum air intake length for each boiler is
fifty (50) equivalent feet.
Common systems may use outdoor temperature, return
water temperature or both to stage the boilers.
3. Locate air intake termination on the same wall as
the vent termination if possible, to prevent nuisance
boiler shutdowns. However, boiler may be installed
with vertical venting and sidewall combustion air
ꢂꢀ
ꢂꢁ
VIII. System Start-up
or shut-off valve in system supply and return piping.
5. Open hose bib.
A. Safe operation and other performance criteria were
met with gas manifold and control assembly provided
on boiler when boiler underwent tests specified in
American National Standard for Gas-Fired Low-
Pressure Steam and Hot Water Boilers, ANSI Z21.13.
6. Open fill valve (Make-up water line should be
located directly after full port ball valve in system
supply piping between air scoop and expansion
tank).
B. Verify that the venting, water piping, gas piping and
electrical system are installed properly. Refer to
installation instructions contained in this manual.
7. Allow water to overflow from bucket until discharge
from hose is bubble free for 30 seconds.
C. Confirm all electrical, water and gas supplies are
turned off at the source and that vent is clear of
obstructions.
8. Close the opened zone valve or shut-off valve for
the zone being purged of air, then open the zone
valve or shut-off valve for the next zone to be
purged. Repeat this step until all zones have been
purged. At completion, open all zone valves or
shut-off valves.
D. Confirm that all manual shut-off gas valves between
the boiler and gas source are closed.
9. Close hose bib, continue filling the system until the
pressure gauge reads 12 psi. Close fill valve.
WARNING
Completely read, understand and follow all
instructions in this manual before attempting
start up.
(Note - If make-up water line is equipped with
pressure reducing valve, system will automatically
fill to 12 psi. Follow fill valve manufacturer’s
instructions).
E. Fill entire heating system with water and vent air
from system. Use the following procedure on a Series
Loop or multi-zoned system installed as per Figure 25
or 26 to remove air from system when filling.
10.Open isolation valve in boiler supply piping.
11.Remove hose from hose bib.
F. Confirm that the boiler and system have no water
leaks.
WARNING
G. Prepare to check operation.
The maximum operating pressure of this boiler
is ꢁ0 psig. Never exceed this pressure. Do not
plug or change pressure relief valve.
1. Obtain gas heating value (in Btu per cubic foot)
from gas supplier.
2. Connect manometer to pressure tap on gas valve.
Use 1/8 NPT tapping provided.
NOTICE
3. Temporarily turn off all other gas-fired appliances.
If it is required to perform a long term pressure
test of the hydronic system, the boiler should
first be isolated to avoid a pressure loss due to
the escape of air trapped in the boiler.
4. Turn on gas supply to the boiler gas piping.
5. Confirm that the supply pressure to the gas valve is
14 in. w.c. or less. Refer to Table 5 for minimum
supply pressure.
To perform a long term pressure test including
the boiler, ALL trapped air must first be removed
from the boiler.
6. Open the field installed manual gas shut-off valve
located upstream of the gas valve on the boiler.
7. Using soap solution, or similar non-combustible
solution, electronic leak detector or other approved
method. Check that boiler gas piping valves, and
all other components are leak free. Eliminate any
leaks.
A loss of pressure during such a test, with no
visible water leakage, is an indication that the
boiler contained trapped air.
1. Close full port ball valve in boiler supply piping.
2. Isolate all zones by closing zone valves or shut-off
valves in supply and return of each zone(s).
DANGER
Do not use matches, candles, open flames or
other ignition source to check for leaks.
3. Attach a hose to the vertical hose bib located prior to
the full port ball valve in the system supply piping.
(Note - Terminate hose in five gallon bucket at a
suitable floor drain or outdoor area).
8. Purge gas line of air.
4. Starting with one circuit at a time, open zone valve
ꢂ4
Figure ꢁꢂ: Operating Instructions
ꢂ5
H. Operating Instructions.
numbers in the wiring ladder diagrams. The yellow
LED indicates the status of the flame, see Table 11.
The green LED indicates the status of the system,
see Table 12. See Figure 37 for LED locations. See
Figure 38 for Troubleshooting Guide.
1. Follow Operating Instructions to place boiler in
operation. See Figure 36.
2. Electronic Ignition Modules with LED indicators.
Table 10 cross-references the ignition module
terminal designations to the ignition terminal
TABlE 10: IGNITION MODUlE TERMINAl
CROSS-REFERENCE
Ignition Module
Terminal Designation
Wiring Ladder Diagram
Terminal Number
MV
MV/PV
PV
1
2
3
GND
4
24V (GND)
5
24V
6
SPARK
9
Figure ꢁ7: lED locations
TABlE 11: yEllOW lED FlAME CODES
Yellow LED
Indicates
Recommended Service Action
Flash Codea
Heartbeat
Normal Flame Signal
N/A
Weak Flame Signal -
System will operate reliably but flame signal is
less than desired.
Note: This indication may flash temporarily
during or shortly after lightoff on some appli-
cations.
Perform routine maintenance to
assure optimum flame signal.
2
Marginal Flame Signal (less than 1.1 µA) -
System may not operate reliably over time.
Service call recommended.
Note: This indication may flash temporarily
during or shortly after lightoff on some appli-
cations.
Check gas supply, pilot burner, flame
sense wiring, contamination of flame
rod, burner ground connection.
1
No Flame or Flame Signal -
below minimum threshold for system
operation.
OFF
N/A
aFlash Code Descriptions
- Heartbeat: Constant ½ second bright, ½ second dim cycles.
- The flash code number signifies that the LED flashes X times at 2Hz, remains off for two
seconds, and then repeats sequence.
ꢂꢂ
TABlE 1ꢀ: GREEN lED STATUS CODES
Green LED
Flash Code
Indicates
Next System Action
Recommended Service Action
(X + Y)a
OFF
No “Call for Heat”
N/A
N/A
N/A
None
None
None
Startup - Flame sense
calibration
Flash Fast
Heartbeat
Normal operation
If system fails to light on next trial
for ignition check gas supply, pilot
burner, spark and flame sense wir-
ing, flame rod contamination or out
of position, burner ground connec-
tion.
5 minute Retry Delay-
Pilot flame not detected
during trial for ignition
Initiate new trial for ignition after retry
delay completed.
2
If system fails to light on next trial
for ignition check gas supply, pilot
burner, flame sense wiring, flame
rod contamination, burner ground
connection.
Initiate new trial for ignition. Flash
code will remain through the ignition
trial until flame is proved.
Recycle- Flame failed
during run
3
4
If situation self corrects within 10
Check for pilot flame. Replace gas
valve if pilot flame present. If no
pilot flame, cycle “Call for Heat.” If
error repeats, replace control.
seconds, control returns to normal
sequence. If flame out of sequence re-
mains longer than 10 seconds, control
goes to Flash code 6+4 (see below)
Flame sensed out of
sequence
Check flame sense lead wire for
damage or shorting. Check that
the fault corrects, control resumes nor- flame rod is in proper position.
mal operation after a one minute delay. Check flame rod ceramic for cracks,
damage or tracking.
Control remains in wait mode. When
Flame sense leakage to
ground
7
Check transformer and AC line for
Control remains in wait mode. When
proper input voltage to the control.
Low secondary voltage
supply- (below 15.5 Vac)
8
the fault corrects, control resumes nor-
Check with full system load on the
mal operation after one minute delay.
transformer.
Check gas supply, pilot burner, spark
5 minute Retry Delay-
On every third retry on
same “Call for Heat”
Initiate new trial for ignition after retry
delay completed.
and flame sense wiring, flame rod
contamination or out of position,
burner ground connection.
6 + 2
6 + 3
6 + 4
ON
On every 6th flame
failure during run on the
same “Call for Heat”
Check gas supply, pilot burner, flame
sense wiring, contamination of flame
rod, burner ground connection.
5 minute retry delay, then initiate new
trial for ignition.
Control waits until flame is no longer
sensed and then goes to soft lockout.
Flash code continues. Control auto
Check for pilot flame. Replace gas
valve if pilot flame present. If no
pilot flame, cycle “Call for Heat.” If
Flame sensed out of
sequence- longer than
10 seconds
resets from soft lockout after one hour. error repeats, replace control.
Soft lockout due to error
detected during self
check sequences
Control auto resets from soft lockout
after one hour.
Reset by cycling “Call for Heat.” If
error repeats, replace the control
aFlash Code Descriptions:
-
-
-
Flash Fast: rapid blinking
Heartbeat: Constant ½ second bright, ½ second dim cycles.
A single flash code number signifies that the LED flashes X times at 2Hz, remains off for two seconds, and then
repeats the sequence.
-
X + Y flash codes signify that the LED flashes X times at 2Hz, remains off for two seconds, flashes Y times at 2
Hz, remains off for three seconds, and then repeats the sequence.
ꢂ7
honeywell Electronic Ignition Troubleshooting Guide
Figure ꢁ8: Troubleshooting Guide
ꢂ8
Figure 40: 1 Inch Main Burner flame
Figure 41: Pilot Burner Flame
tipping. Orange-yellow streaks should not be confused
with true yellow tipping.
L. Check thermostat operation. Raise and lower
temperature setting to start and stop boiler operation.
M. Check ignition control module shut-off. Disconnect
pilot lead wires from gas valve. If burners do not
shutdown, determine cause of malfunction. Replace
necessary items and check operation.
Figure 39: Sequence of Operation
N. Check low water cutoff (if so equipped).
1. Adjust thermostat to highest setting.
I. Sequence of Operation. See Figure 39. If boiler fails
to operate properly, see Troubleshooting Tree in Section
IX: Service.
2. With boiler operating, open drain valve and slowly
drain boiler.
3. Main burners and pilot burner will extinguish and
blower will stop when water level drops below low
water cutoff probe. Verify limit, thermostat or other
controls have not shut off boiler.
J. Check pilot burner flame. See Figure 41. Flame
should be steady, medium hard blue enveloping 3/8 to
½ inch of sensing probe.
K. Check main burner flame. See Figures 40. Flame
4. Adjust thermostat to lowest setting. Refill boiler.
should have clearly defined inner cone with no yellow
ꢂ9
more than 0.3 inch w.c. If measured input rate is
still less than 98% of rated input:
O. Check limit.
1. Adjust thermostat to highest setting.
i. Remove Main Burners per procedure in
Section IX: Service.
ii. Remove gas orifices. Drill one (1) drill size
larger (drill size is stamped on orifice, or see
Section X: Repair Parts).
2. Observe temperature gauge. When temperature is
indicated, adjust limit to setting below observed
temperature. Main burners and pilot burner should
extinguish, and blower should stop.
3. Adjust limit to setting above observed temperature.
Ignition sequence should begin.
iii. Reinstall gas orifices and main burners.
Measure input rate.
4. Adjust thermostat to lowest setting. Adjust limit to
desired setting.
6. Recheck Main Burner Flame.
7. Return other gas-fired appliances to previous
P. Adjust gas input rate to boiler.
conditions of use.
1. Adjust thermostat to highest setting.
Q. Review User’s Information Manual and system
2. Check manifold gas pressure. See Table 5 or rating
label located in the boiler’s vestibule compartment.
Adjust gas valve pressure regulator as necessary
(turn adjustment screw counterclockwise to
decrease manifold pressure, or clockwise to increase
manifold pressure). If pressure cannot be attained,
check gas valve inlet pressure. If less than minimum
indicated in Table 5 or boiler’s rating label, contact
gas supplier for assistance.
operation with owner or operator.
TABlE 1ꢁ: GAS FlOW RATE IN CUBIC FEET
PER hOUR
Seconds
for One
Revolution
Size of Gas Meter Dial
One-Half
One
Two
Cu. Ft.
Cu. Ft.
Cu. Ft.
30
32
34
36
38
40
42
44
46
48
50
52
54
56
58
60
60
120
113
106
100
95
240
225
212
200
189
180
172
164
157
150
144
138
133
129
124
120
3. Clock gas meter for at least 30 seconds. Use Table
13 to determine gas flow rate in Cubic Feet per
Hour.
56
53
50
WARNING
47
Failure to properly adjust gas input rate will result
in over firing or under firing of the appliance.
Improper and unsafe boiler operation may result.
45
90
43
86
41
82
4. Determine Input Rate. Multiply gas flow rate by gas
39
78
heating value.
37
75
5. Compare measured input rate to input rate stated on
rating plate.
36
72
35
69
a. Boiler must not be over fired. Reduce input rate
by decreasing manifold pressure. Do not reduce
more than 0.3 inch w.c. If boiler is still overfired,
contact your Burnham distributor or Regional
Office for replacement Gas Orifice.
33
67
32
64
31
62
30
60
b. Increase input rate if less than 98% of rating
plate input. Increase manifold gas pressure no
70
IX. Service
DANGER
This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high
pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool
before attempting any disassembly or service.
Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly
or service.
Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify,
remove or tamper with any control device.
WARNING
This boiler must only be serviced and repaired by skilled and experienced service technicians.
If any controls are replaced, they must be replaced with identical models.
Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.
If any electrical wires are disconnected during service, clearly label the wires and assure that the wires
are reconnected properly.
Never jump out or bypass any safety or operating control or component of this boiler.
Read, understand and follow all the instructions and warnings contained in All of the component
instruction manuals.
Assure that all safety and operating controls and components are operating properly before placing
the boiler back in service.
A. General. Inspection and service should be conducted
annually. Turn off electrical power and gas supply while
conducting service or maintenance. Follow instructions
TO TURN OFF GAS TO APPLIANCE. See Figure 36.
4. Pipe must be supported at minimum five (5) foot
intervals and must not sag.
5. All vent joints must be secure and watertight.
6. All air intake joints must be secure and airtight.
Horizontal vent tee drain or vertical vent tee drain
(if used) must have minimum 6 inch trap and allow
condensate to flow freely. To Clean:
B. Low water cutoff (if so equipped).
Probe Type (Annual Service). Probe type LWCO
should be removed once a year, examined and
cleaned of any dirt accumulations to assure proper
operations. Do not attempt to repair mechanisms in the
field. Complete replacement mechanisms, including
necessary gaskets and installation instructions, are
available from the manufacturer.
a. Disconnect drain tube from drain fitting.
b. Flush drain tube with water. Fill trap with water.
c. Securely fasten drain tube to drain fitting,
providing gas-tight and watertight seal.
7. If pipe must be disassembled for removal of
obstructions or resealing of joint, see Section III,
Paragraph C.
C. Vent/Air Intake System. Inspect for obstructions, soot
accumulation, proper support, and deterioration of pipe,
fittings, and joints.
D. Boiler Flue Passages. Inspect for blockage or soot
accumulation.
1. Clean terminal screens. Terminals must be free of
obstruction, undamaged, with screens securely in
place.
1. Remove Main Burners. See Figure 44.
a. Remove front door.
2. Terminal and wall thimbles (if used) must be
weathertight.
b. Remove air intake box front door.
i. Remove sheet metal screws.
3. Pipe must be full round shape, and show no damage
from impact or excessive temperature.
c. Disconnect pilot tubing and pilot lead wires at
the gas valve.
71
d. Remove wires to Flame Roll-out Switch.
e. Remove air diffuser screen.
f. Remove Burner Access Panel.
g. Mark location of Main Burner with Pilot Bracket
on gas manifold.
h. Hold Main Burner on throat. Lift front of
burners to clear orifice. Burner which holds pilot
can be removed by lifting the burner adjacent to
its right first.
2. Disconnect Vent Connector and Vent Pipe from
Blower Outlet
3. Remove Jacket Top Panel.
4. Disconnect the Black and Gary Silicone Tubing
from the Canopy.
5. Disconnect Wiring Harness from Blower Motor.
6. Remove Canopy/Blower Assembly.
Figure 4ꢀ: Silicone Tubing Assembly
a. Loosen the (4) screws from Canopy.
13. Install Jacket Top Rear Panel.
7. Remove Flue Gas Baffles. Inspect Flue Gas Baffles
14. Connect Vent System. See Figure 43.
15. Connect Blower Motor Wiring Harness.
for deterioration.
8. Inspect flue passages. Clean with flue brush. See
Figure 44.
9. Inspect heating surface in combustion chamber.
Clean with straight handle wire brush.
10. Install Flue Gas Baffles.
11. Replace Canopy/Blower Assembly.
12. Connect Silicone Tubing between Pressure Fittings
on Canopy Assembly and Pressure Switch. Route
through bushings in Vestibule Panel . See Figure
42.
Figure 4ꢁ: Blower Vent Connector Assembly
TABlE 14: PIlOT BURNER lOCATION
Boiler Model
Main Burner with Pilot Bracket
Pilot Burner Located Between Main Burners *
SCG-3
SCG-4
SCG-5
SCG-6
SCG-7
SCG-8
SCG-9
2
3
4
5
6
7
8
2 & 3
3 & 4
4 & 5
5 & 6
6 & 7
7 & 8
8 & 9
* Main burners numbered left to right as viewed from front of boiler.
7ꢀ
7ꢁ
E. Main Burners and Firebox.
NOTE: If switch drops-out before boiler reaches
temperature or if pressure differential readings are
below minimums shown in Table 15, check for
cracks in hose or contact your nearest Burnham
representative.
1. Vacuum firebox. Exercise care - do not damage base
insulation.
2. Clean main burners. Brush top of burners with soft
bristle brush. See Figure 44. Vacuum to remove any
dirt and lint.
4. Stop boiler, remove manometer and reconnect hoses
to differential pressure switch. See Figures 42 and
45.
3. Vacuum tip of pilot burner.
4. Check gas orifices for lint and dirt. Clean as
necessary.
5. Install main burners by reversing procedure to
remove burners.
a. Pilot burner must be installed in original
location. See Table 14.
b. Main burners must be properly secured in burner
tray slot at rear of firebox and over gas orifice.
See Figure 44.
c. Pilot gas supply and pilot lead wires must be
reconnected.
d. Burner access panel must be securely in place.
e. Reinstall air diffuser screen.
f. Reconnect Flame Roll-out wires.
g. Air Intake Box Front Door must be installed.
F. Check operation. Follow steps G through P from
Section VIII: System Start-up.
G. Procedure for Measuring Differential Pressure (See
Figure 45).
1. With boiler off, remove Gray and Black Hoses at
differential pressure switch.
2. With tees and ¼ inch aluminum stubs, connect water
manometer as shown with additional tubing.
3. Start boiler and read Pressure on Manometer
when boiler water temperature reaches operating
temperature. Refer to Table 15 for minimum
readings.
Figure 45: Differential Pressure Measurement
TABlE 15: DIFFERENTIAl PRESSURE SWITCh SETTINGS
Minimum Differential Pressure
Boiler Model
Sea Level to 4,999 Ft.
5,000 - 10,000 Ft. Elevation
SCG-3
SCG-4
SCG-5
SCG-6
SCG-7
1.32” w.c.
1.17” w.c.
1.17” w.c.
.88” w.c.
.80” w.c.
.80” w.c.
.65” w.c.
.65” w.c.
.35” w.c.
.30” w.c.
SCG-8
.88” w.c.
.88” w.c.
.35” w.c.
.35” w.c.
SCG-9
74
ThIS PAGE lEFT INTENTIONAlly BlANk
75
7ꢂ
77
XI. Repair Parts
All SCG Repair Parts may be obtained through your local Burnham Wholesale distributor.
Should you require assistance in locating a Burnham distributor in your area, or have questions
regarding the availability of Burnham products or repair parts, please contact Burnham
Customer Service at (717) 481-8400 or Fax (717) 481-8408.
78
[Quantity] Part Number
Key
No.
Description
SCG-3
SCG-4
SCG-5
SCG-6
SCG-7
SCG-8
SCG-9
1. CASTING ASSEMBly
1
Section Assembly
61707031
61707041
61707051
61707061
71707001
61707071
61707081
61707091
1A Left End Section
(1)
71707003
(2)
71707003
(3)
71707003
(4)
71707003
(5)
71707003
(6)
71707003
(7)
71707003
1B
Center Section
1C Right End Section
1D Slip Nipple, #3
71707002
(10)
(4)
(6)
(8)
(12)
(14)
(16)
806600009 806600009 806600009 806600009 806600009 806600009 806600009
(2)
71107002
(3)
71107002
(4)
71107002
(5)
71107002
(6)
71107002
(7)
71107002
(8)
71107002
1E
1F
Flue Gas Baffle
Tie Rod, ¼” -20
(2)
(2)
(2)
(2)
(2)
(2)
(2)
100109-01 100108-05 100108-07 100108-13 100108-14 100108-15 100108-16
1G Hex Nut, ¼” -20
(4) 80860407
79
80
[Quantity] Part Number
Key
No.
Description
SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8
SCG-9
ꢀ. BASE ASSEMBly
2A Base Wrapper
71807031 71807041 71807051 71807061 71807071 71807081 71807091
2B Base Tray
71807032 71807042 71807052 71807062 71807072 71807082 71807092
2C Burner Tray Assembly
2D Base Front Panel
61807031 61807041 61807051 61807061 61807071 61807081 61807091
71807035 71807045 71807055 71807065 71807075 71807085 71807095
2E Burner Access Panel
71807036 71807046 71807056 71807066 71807076 71807086 71807096
2F Cerafelt Gasket 1/2” x 2”
2G Cerafelt Gasket 1/2” x 2”
2H Base Side Insulation
9206003
9206003
(2) 72007001
2J Base Rear Insulation
72007031 72007041 72007051 72007061 72007071 72007081 72007091
2K Base Front Insulation
2L Base Leg Assembly
72007032 72007042 72007052 72007062 72007072 72007082 72007092
(4) 6186001
(18) 80860700
80160044
2M Self Tapping Screw, 1/4” -20 x 1/2”
2N Flame Roll-out Switch
2P Sheet Metal Screw, #8 x 3/4”
2Q Self Tapping Screw, 10 -32 x 3/8”
2R Self Tapping Screw Hex Cap, 5/16 -18 x 1-1/4”
80860030
(5) 80860705
(6) 80860705
(4) 80860717
(7) 80860705
81
8ꢀ
[Quantity] Part Number
SCG-5 SCG-6 SCG-7
Key
No.
Description
SCG-3
SCG-4
SCG-8
SCG-9
ꢀ. BASE ENClOSURE ASSEMBly
3A Air Box Assembly
61807032 61807042 61807052 61807062 61807072 61807082 61807092
71807034 71807044 71807054 71807064 71807074 71807084 71807094
3B Air Box Door
3C Combustion Air Diffuser
3D Pilot Tube Gasket Cover Plate
3E Pilot Tube Gasket
N/A
71807049 71807059 71807069 71807079 71807089 71807099
7096002
8206038
3F Window Plug
102202-01
(6) 80860000
3J Sheet Metal Screws #8 x 1/2”
3K Self Tapping Screw, 10-32 x 3/8”
(18) 80860705
(22) 80860705
8ꢁ
84
[Quantity] Part Number
SCG-5 SCG-6 SCG-7
Key
No.
Description
SCG-3
SCG-4
SCG-8
SCG-9
4. FAN/CANOPy ASSEMBly
Canopy Assembly - Sea Level
4A
61107031 61107041 61107051 61107061 61107071 61107081 61107091
Canopy Assembly - High Altitude
61107032 61107042 61107052 61107062 61107072 61107082 61107092
4B Cerafelt
9206005
(4) 80861512
(4) 808600141
8206085
4C U-Clip
4D Sheet Metal Screw, #10 x 1”
4E Fan Gasket
4F Fan
81161512
4G Lock Washer, #10
4H Machine Screw, #10-24 x 2½”
(4) 80860636
(4) 808608982
85
8ꢂ
[Quantity] Part Number
SCG-5 SCG-6 SCG-7
Key
No.
Description
SCG-3
SCG-4
SCG-8
SCG-9
5. BURNER ASSEMBlIES
Gas Valve (Natural Gas),
Honeywell VR8204P1171
81660282
N/A
Gas Valve (Natural Gas),
Honeywell VR8304P4496
N/A
81660146
N/A
81660283
N/A
5A
Gas Valve (LP Gas),
Honeywell VR8204C3015
Gas Valve (LP Gas),
Honeywell VR8304P4280
81660160
Nipple, ½” NPT x Close
5B
806600040
N/A
N/A
806600022
N/A
Nipple, ¾” NPT x Close
Union, ½” NPT
5C
806604023
N/A
Union, ¾” NPT
806604001
---
½” Gas Manifold
5D
82207031
82207041
82207051 82207061
---
---
¾” Gas Manifold
---
---
---
---
82207071 82207081
82207191
(4)
822710
(6)
822710
(8)
822710
(10)
822710
(12)
822710
(14)
822710
(16)
822710
Burner Orifices - Natural Gas #47
5E
(4)
822792
(6)
822792
(8)
822792
(10)
822792
(12)
822792
(14)
822792
(16)
822792
Burner Orifices - LP Gas 1.20 mm
Pilot Assembly - Natural Gas
5F
8236163
8236164
100147-01
(9)
Pilot Assembly - LP Gas
5G Pilot Burner
(3)
(5)
(7)
(11)
(13)
(15)
5H Main Burner
100146-01 100146-01 100146-01 100146-01 100146-01 100146-01 100146-01
5J Pilot Tubing
8236122
5K Self Tapping Screw, ¼ - 20 x ½”
(6) 80860700
87
88
[Quantity] Part Number
SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9
Key
No.
Description
ꢂ. CONTROl PANEl ASSEMBly
6A Limit, Honeywell L4080D
100189-01
80160155U
100959-01
80160096U
6B Transformer/Relay, Honeywell R8285D
6C Ignition Module, Honeywell S8670E3003
6D Blower Relay, Honeywell R8222U1006
Differential Pressure Switch
Sea Level 0’ - 4999’
80160762
80160759
80160761
80160763
80160760 80160759
80160760
80160764
6E
High Altitude - 5000’ - 10,000’
80160764 80160765
8136259
6F Junction Box
89
90
[Quantity] Part Number
Key
No.
Description
SCG-3
SCG-4
SCG-5
SCG-6
SCG-7
SCG-8
SCG-9
7. JACkET PARTS
7A Jacket Left Side Panel
7B Jacket Right Side Panel
7C Rear Panel
60407002
60407001
60407033 60407043 60407053 60407063 60407073 60407083 60407093
60407034 60407044 60407054 60407064 60407074 60407084 60407094
60407032 60407042 60407052 60407062 60407072 60407082 60407092
101354-03 101354-04 101354-05 101354-06 101354-07 101354-08 101354-09
7D Vestibule Panel
7E Top Panel
7F Front Door
7G Air Intake Collar Assembly
7H Handle
60407003
60407004
8056184
60407005
7J Door Clip
(2) 7041921
8136048
7K Bushing
7L Burnham Logo
81460099
91
[Quantity] Part Number
Key
No.
Description
SCG-3
SCG-4
SCG-5
SCG-6
SCG-7
SCG-8
SCG-9
8. MISCEllANEOUS PARTS CARTON
8A Water Manifold
80607001
8056169
8B Temperature/Pressure Gauge
8C Circulator Wiring Harness
8D Safety Relief Valve
8E Boiler Drain Valve
8F Vent Terminal
6130701
81660363
806603061
8110701
6116044
8110703
8110702
6116063
8110704
8G Air Intake Terminal
8H Vent Connector
6116045
9ꢀ
Important Product Safety Information
Refractory Ceramic Fiber Product
Warning:
The Repair Parts list designates parts that contain refractory ceramic fibers
(RCF). RCF has been classified as a possible human carcinogen. When
exposed to temperatures about 1805°F, such as during direct flame contact,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
• Take steps to assure adequate ventilation.
• Wash all exposed body areas gently with soap and water after contact.
• Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
• Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
• If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
• If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
• If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
• Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.
9ꢁ
SERVICE RECORD
DATE
SERVICE PERFORMED
94
SERVICE RECORD
DATE
SERVICE PERFORMED
95
LimitedWarranty
FOR RESIDENTIAL CAST IRON WATER BOILERS
water boiler for its intended purposes and its maintenance
Subject to the terms and conditions set forth below, U.S. Boiler™
Co., Inc. Lancaster, Pennsylvania hereby extends the following limited
warranties to the original owner of a residential grade water boiler
manufactured and shipped on or after July 1,1991:
accordance with U. S. Boiler Co., Inc. recommendations and
hydronics industry standards. These warranties will be inapplicable if
the residential grade water boiler is used or operated over its rated
capacity, is subjected to unauthorized modification, or is damaged as
a result of being otherwise improperly operated or serviced including,
but not limited to, damage from any of the following: operation with
insufficient water, allowing the boiler to freeze, subjecting the boiler
to flood conditions, and operation with unapproved water or fuel
additives which cause deposits or corrosion.
ONE YEAR LIMITED WARRANTY
ON RESIDENTIAL GRADE WATER BOILERS
U.S. Boiler Co., Inc. warrants to the original owner that its residential
grade water boilers comply at the time of manufacture with recognized
hydronic industry standards and requirements then in effect and will be
free of defects in material and workmanship under normal usage for a
period of one year from the date of original installation. If any part of a
water boiler is found to be defective in material or workmanship during
this one year period, U.S. Boiler Co., Inc. will, at its option, repair or
replace the defective part.
5. Removal and Installation: These warranties do not cover expenses of
removal or reinstallation. The owner is responsible for the cost of
removing and reinstalling any defective part and its replacements
and all labor and material connected therewith.
6. Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach of
these warranties is limited to the repair or replacement of its parts in
accordance with the terms and conditions of these warranties.
LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER
U.S. Boiler Co., Inc. warrants to the original owner that the heat
exchanger of its residential grade water boilers will remain free from
defects in material and workmanship under normal usage for the lifetime
of the original owner at the original place of installation. If a claim is
made under this warranty during the first ten years from the date of
original installation, U.S. Boiler Co., Inc. will, at its option, repair or
replace the heat exchanger. If a claim is made under this warranty after
the expiration of ten years from the date of original installation, U.S.
Boiler Co., Inc. will, at its option and upon payment of the pro-rated
service charge set forth below, repair or replace the heat exchanger.
The service charge applicable to a heat exchanger warranty claim is
based upon the number of years the heat exchanger has been in
service and will be determined as a percentage of the retail price of the
heat exchanger model involved at the time the warranty claim is made
as follows:
7. Limitation of Damages: Under no circumstances shall U.S. Boiler
Co., Inc. be liable for incidental, indirect, special or consequential
damages of any kind whatsoever under these warranties, including,
but not limited to, injury or damage to persons or property and
damages for loss of use, inconvenience or loss of time. U.S. Boiler
Co., Inc. liability under these warranties shall under no circumstances
exceed the purchase price paid by the owner for the residential grade
water boiler involved. Some states do not allow the exclusion or
limitation of incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
8. Limitation of Warranties: These warranties set forth the entire
obligation of U.S. Boiler Co., Inc. with respect to any defect in a
residential grade water boiler and U.S. Boiler Co., Inc. shall have no
express obligations, responsibilities or liabilities of any kind
whatsoever other than those set forth herein. These warranties are
given in lieu of all other express warranties.
Years
In Service
1-10
11
5
12
10
13
15
14
20
15
25
16
30
17
35
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING
ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION
TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED
Service Charge
as % of
No
Charge
Retail Price
WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN
A RESIDENTIAL GRADE WATER BOILER SHALL EXTEND TO THE
ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER
AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO
NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY
LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
Years
In Service
25 and
above
18
40
19
45
20
50
21
55
22
60
23
65
24
70
Service Charge
as % of
Retail Price
75
NOTE: If the heat exchanger model involved is no longer available due
to product obsolescence or redesign, the value used to establish the
retail price will be the published price as shown in the Burnham
Hydronics Repair Parts Price Sheet where the heat exchanger last
appeared or the current retail price of the then nearest equivalent heat
exchanger.
PROCEDURE FOR OBTAINING WARRANTY SERVICE
In order to assure prompt warranty service, the owner is requested to
complete and mail the attached Warranty Card within ten days after the
installation of the boiler, although failure to comply with this request will
not void the owner’s rights under these warranties.
Upon discovery of a condition believed to be related to a defect in
material or workmanship covered by these warranties, the owner should
notify the installer, who will in turn notify the distributor. If this action is
not possible or does not produce a prompt response, the owner should
write to U.S. Boiler Co., Inc., Burnham Hydronics, at P.O. Box 3079,
Lancaster, PA 17604, giving full particulars in support of the claim.
ADDITIONAL TERMS AND CONDITIONS
1. Applicability: The limited warranties set forth above are extended
only to the original owner at the original place of installation within the
United States and Canada. These warranties are applicable only to
water boilers designated as residential grade by U.S. Boiler Co., Inc.
and installed in a single or two-family residence and do not apply to
steam boilers of any kind or to commercial grade boilers.
The owner is required to make available for inspection by U.S. Boiler
Co., Inc. or its representative the parts claimed to be defective and, if
requested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S.
Boiler Co., Inc. at the above address for inspection or repair. In
addition, the owner agrees to make all reasonable efforts to settle any
disagreement arising in connection with a claim before resorting to legal
remedies in the courts.
2. Components Manufactured by Others: Upon expiration of the one
year limited warranty on residential grade water boilers, all boiler
components manufactured by others but furnished by U.S. Boiler
Co., Inc. (such as oil burner, circulator and controls) will be subject
only to the manufacturer’s warranty, if any.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND
YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE
TO STATE.
3. Proper Installation: The warranties extended by U.S. Boiler Co., Inc.
are conditioned upon the installation of the residential grade water
boiler in strict compliance with U.S. Boiler Co., Inc. installation
instructions. U. S. Boiler Co., Inc. specifically disclaims liability of any
kind caused by or relating to improper installation.
4. Proper Use and Maintenance: The warranties extended by U.S.
Boiler Co., Inc. conditioned upon the use of the residential grade
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