Burnham SCG 1100-H4 User Manual

8140705R9-10/08 As an ENERGY STAR® Partner, Burnham Hydronics has determined that the SCG meets the ENERGY STAR® guidelines for energy efciency est

10A. Vent Guidelines Due to Removal of an Existing Boiler For installations not involving the replacement of an existing boiler, proceed to Step B.

11with at least one side open, similar to a joist bay application. Use double wall thimble [Burnham Part No. 8116115 (3”), 100185-01 (4”)] when penet

12a. Wipe the male end of each joint using an alcohol pad to remove any dirt and grease.b. Align weld seams in pipes and use a slight twisting motio

13Figure 4A: Recommended Separate Horizontal – Vent/Air Intake Installation

14Figure 4B: Alternate Separate Horizontal – Vent/Air Intake Installation

15Figure 5A: Separate Horizontal – Vent/Air Intake Terminal Conguration (SCG-3 thru 7)

16Figure 5B: Separate Horizontal – Vent/Air Intake Terminal Conguration (SCG-8 and 9)

17Vertical Venting –1. See Figure 43 on Page 72 for Blower Vent Connector Assembly. Do not exceed maximum vent lengths. Refer to Table 4.2. Insta

18d. Install storm collar on air intake pipe immediately above ashing. Apply Dow Corning Silastic 732 RTV Sealant between air intake pipe and storm

19Figure 7: Attic OffsetFigure 6: Vertical Vent Installation

2IMPORTANT INFORMATION - READ CAREFULLYNOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area

20Figure 8A: Vertical Vent/Air Termination (3” Vent Terminal)Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal

21Figure 8B: Vertical Vent/Air Termination (4” Vent Terminal)Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal

22Figure 9: Vertical Air Intake Piping

23COMBINATION HORIZONTAL VENT SYSTEM COMPONENTSF. Combination Horizontal Venting System –SCG-3 Through SCG-6 ONLY – See Figures 10 and 11.1. Do not

24c. From exterior of building, insert air box sub-assembly into square opening. Push air box inward until wall ange is against wall, check for lev

25Figure 10: Combination Horizontal – Vent/Air Installation (SCG-3 thru 6)

26Figure 11: Combination Horizontal – Vent/Air Terminal Installation (SCG-3 thru 6)

27G. Combination Vertical Venting System – SCG-3 Through SCG-6 ONLY – See Figures 12, 13 and 14.NOTICEThis vent system requires components not suppli

281. Saf-T Vent SC is an advanced concentric vent system designed for zero clearance installation in residential applications. The inner wall is con

29• For a venting system that extends through any zone above that on which the connected appliance is located (except for one and two family dwelling

3WARNINGThis boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.Improper installatio

307. Joint Assembly Instructions:a. Before joining the sections or ttings together, use an alcohol pad to wipe the joint area of both ends of the i

318. Straight Sections Cut To Length: If a custom length of SC is necessary, a standard vent section can be cut.a. Measure the distance of the leng

329. Air Intake Connections for Direct Vent and Sealed Combustion Appliances*: The Air Intake Tee may be used on approved direct vent and sealed com

3311. Horizontal Supports: Saf-T Vent SC must have supports for every six (6) feet of horizontal run and after every transition from vertical to hor

34 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 us

35 Fire Stop/Wall Thimble/Support, (SC_ _FS): • The Saf-T Vent SC Fire Stop can be used as a restop, a wall thimble, or as a support plate. • To u

36 Vertical Terminations, (SC_ _VT): Install the vertical termination adapter into the last vent section and secure with the three (3) self-tapping

3711. Install re stops where vent passes through oors, ceilings or framed walls. The re stop must close the opening between the vent pipe and the

38Figure 12: Recommended Separate Horizontal - Vent Installation

39Figure 13: Alternate Separate Horizontal - Vent Installation

4Table of ContentsFigure 1: Minimum Clearances to Combustibles I. Pre-Installation ...6 II. Unpack Boiler ...

40Figure 15: Indoor Air - Vertical Vent Terminal InstallationExtend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal

411. 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

42Figure 18: Optional Separate Horizontal Air 5” Intake Terminal InstallationFigure 19: Optional Separate Horizontal 3” Vent Terminal Installation

43Figure 20: Optional Separate Horizontal 4” Vent Terminal InstallationFigure 21: Optional Separate Horizontal 3” Vent Terminal Installation (Indoor

44Figure 22: Optional Separate Horizontal 4” Vent Terminal Installation (Indoor Air)

45A. Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions.1. There are many poss

46 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 ins

47Figure 24: Supply Water Manifold Piping Install pipe tee between circulator and boiler return along with second tee in supply piping as shown in F

48Figure 25: Recommended Water Piping for Circulator Zoned Heating Systems

49Figure 26: Recommended Water Piping for Zone Valve Zoned Heating Systems

5Figure 2: Dimensions

50V. Gas PipingTABLE 5: GAS RATINGSTABLE 6: SPECIFIC GRAVITY CORRECTION FACTORS FOR NATURAL GASWARNINGFailure to properly pipe gas

51TABLE 7: MAXIMUM CAPACITY OF SCHEDULE 40 PIPE IN CFH* FOR NATURAL GAS PRESSURES OF 0.5 PSIG OR LESS Figure 27: Recommended Gas PipingTABLE 8:

524. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use

53VI. ElectricalA. General. Install wiring and electrically ground boiler in accordance with authority having jurisdiction or, in the absence of suc

54Figure 28: Internal Boiler Wiring Schematic Diagram

55Figure 29: Internal Boiler Wiring Ladder DiagramNOTICEIf an additional system limit is used, install in series with the auxiliary limit jumper show

56D. System Controls and Wiring1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.2.

57Figure 30: System Wiring Schematic for Single Zone Space Heating Only

58Figure 31: Single Zone System with Packaged Alliance™ Water Heater Wiring SchematicNOTICEIf an additional system limit is used, install in series w

59Figure 32: Circulator Zoned System Wiring Schematic

6WARNINGIf you do not follow these instructions exactly, a re or explosion may result causing property damage or personal injury.DANGERDo not

60Figure 33: Zone Valve Zoned System Wiring Schematic

61Figure 34: Different Manufacturer’s Zone Valve Connections to Honeywell R8889

62A. General Guidelines1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual

63Figure 35: Modular Boiler Gas Piping

64A. Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests spe

65Figure 36: Operating Instructions

66H. Operating Instructions.1. Follow Operating Instructions to place boiler in operation. See Figure 36.2. Electronic Ignition Modules with LED i

67Green LED Flash Code(X + Y)aIndicates Next System Action Recommended Service ActionOFF No “Call for Heat” N/A NoneFlash FastStartup - Flame sense ca

68Figure 38: Troubleshooting GuideHoneywell Electronic Ignition Troubleshooting Guide

69I. Sequence of Operation. See Figure 39. If boiler fails to operate properly, see Troubleshooting Tree in Section IX: Service.J. Check pilot burn

7c. 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 shal

70TABLE 13: GAS FLOW RATE IN CUBIC FEET PER HOURO. Check limit.1. Adjust thermostat to highest setting.2. Observe temperature gauge. When tem

71IX. ServiceA. General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or ma

72Figure 42: Silicone Tubing AssemblyFigure 43: Blower Vent Connector Assemblyd. Remove wires to Flame Roll-out Switch.e. Remove air diffuser scre

73Figure 44: Flue and Burner Cleanout, 1” Burner

74Figure 45: Differential Pressure MeasurementTABLE 15: DIFFERENTIAL PRESSURE SWITCH SETTINGSE. Main Burners and Firebox.1. Vacuum rebox. Exercis

75THIS PAGE LEFT INTENTIONALLY BLANK

76

77

78XI. Repair PartsAll SCG Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a

79Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-91. CASTING ASSEMBLY1 Section Assembly 61707031 61707041 61707051 61

8III. Venting / Air Intake PipingTABLE 1: AIR INTAKE / VENT SYSTEM OPTIONSWARNINGDo not use this boiler with galvanized, Type 304 or Type 316 stainl

80

81Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-92. BASE ASSEMBLY2A Base Wrapper 71807031 71807041 71807051 71807061

82

83Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-92. BASE ENCLOSURE ASSEMBLY3A Air Box Assembly 61807032 61807042 618

84

85Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-94. FAN/CANOPY ASSEMBLY4ACanopy Assembly - Sea Level 61107031 61107

86

87Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-95. BURNER ASSEMBLIES5AGas Valve (Natural Gas), Honeywell VR8204P1

88

89Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-96. CONTROL PANEL ASSEMBLY6A Limit, Honeywell L4080D 100189-016B

9TABLE 3: BURNHAM VENT SYSTEM AND AIR INTAKE SYSTEM COMPONENTSTABLE 2: VENT SYSTEM COMPONENTS INCLUDED WITH BOILERTABLE 4: VENT/AIR INTAKE LENGTHVe

90

91Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-97. JACKET PARTS7A Jacket Left Side Panel 604070027B Jacket Right

92Key No.Description[Quantity] Part NumberSCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-98. MISCELLANEOUS PARTS CARTON 8A Water Manifold 806070018B Temp

93Important Product Safety InformationRefractory Ceramic Fiber ProductWarning:The Repair Parts list designates parts that contain refractory ceramic f

94SERVICE RECORDDATE SERVICE PERFORMED

95SERVICE RECORDDATE SERVICE PERFORMED

9679water boiler for its intended purposes and its maintenanceaccordance with U. S. Boiler Co., Inc. recommendations andhydronics industry standards.