Burnham SCG Operations Instructions

8140705R12 - 5/11 As an ENERGY STAR® Partner, Burnham by U.S. Boiler Company has determined that the SCG meets the ENERGY STAR® guidelines for energ

10TABLE 3: VENT SYSTEM AND AIR INTAKE SYSTEM COMPONENTSTABLE 2: VENT SYSTEM COMPONENTS INCLUDED WITH BOILERTABLE 4: VENT/AIR INTAKE LENGTHVent Syst

11A. Vent Guidelines Due to Removal of an Existing Boiler For installations not involving the replacement of an existing boiler, proceed to Step B.

12with at least one side open, similar to a joist bay application. Use double wall thimble [Part No. 8116115 (3”), 100185-01 (4”)] when penetrating a

13a. 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

14Figure 4A: Recommended Separate Horizontal – Vent/Air Intake Installation

15Figure 4B: Alternate Separate Horizontal – Vent/Air Intake Installation

16Figure 5A: Separate Horizontal – Vent/Air Intake Terminal Conguration (SCG-3 thru 7)

17Figure 5B: Separate Horizontal – Vent/Air Intake Terminal Conguration (SCG-8 and 9)

18Vertical Venting –1. See Figure 43 on Page 73 for Blower Vent Connector Assembly. Do not exceed maximum vent lengths. Refer to Table 4.2. Insta

19d. Install storm collar on air intake pipe immediately above ashing. Apply Dow Corning Silastic 732 RTV Sealant between air intake pipe and storm

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

20Figure 7: Attic OffsetFigure 6: Vertical Vent Installation

21Figure 8A: Vertical Vent/Air Termination (3” Vent Terminal)Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal

22Figure 8B: Vertical Vent/Air Termination (4” Vent Terminal)Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal

23Figure 9: Vertical Air Intake Piping

24Vent Carton Part Number 61106012 (Includes Items Below)Description Component Part NumberA Air Box Sub-Assembly (6” square x 2’ long) 61106011B Ex

25c. 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

26Figure 10: Combination Horizontal – Vent/Air Installation (SCG-3 thru 6)

27Figure 11: Combination Horizontal – Vent/Air Terminal Installation (SCG-3 thru 6)

28G. Combination Vertical Venting System – SCG-3 Through SCG-6 ONLY – See Figures 12, 13 and 14.NOTICEThis vent system requires components not suppli

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

3Special Installation Requirements for MassachusettsA. For all side wall horizontally vented gas fueled equipment installed in every dwelling, buildi

30• 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

317. 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

328. 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

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

3411. 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

35 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

36 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

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

3811. 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

39Figure 12: Recommended Separate Horizontal - Vent Installation

4WARNINGThis boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.Improper installatio

40Figure 13: Alternate Separate Horizontal - Vent Installation

41Figure 15: Indoor Air - Vertical Vent Terminal InstallationExtend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal

421. 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

43Figure 18: Optional Separate Horizontal Air 5” Intake Terminal InstallationFigure 19: Optional Separate Horizontal 3” Vent Terminal Installation

44Figure 20: Optional Separate Horizontal 4” Vent Terminal InstallationFigure 21: Optional Separate Horizontal 3” Vent Terminal Installation (Indoor

45Figure 22: Optional Separate Horizontal 4” Vent Terminal Installation (Indoor Air)

46A. Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions.1. There are many poss

47 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

48Figure 24: Supply Water Manifold Piping Install pipe tee between circulator and boiler return along with second tee in supply piping as shown in F

49Figure 25: Recommended Water Piping for Circulator Zoned Heating Systems

5Table of ContentsFigure 1: Minimum Clearances to Combustibles I. Pre-Installation ... 7 II. Unpack Boiler ...

50Figure 26: Recommended Water Piping for Zone Valve Zoned Heating Systems

51V. Gas PipingTABLE 5: GAS RATINGSTABLE 6: SPECIFIC GRAVITY CORRECTION FACTORS FOR NATURAL GASWARNINGFailure to properly pipe gas

52TABLE 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:

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

54VI. ElectricalA. General. Install wiring and electrically ground boiler in accordance with authority having jurisdiction or, in the absence of suc

55Figure 28: Internal Boiler Wiring Schematic Diagram

56Figure 29: Internal Boiler Wiring Ladder DiagramNOTICEIf an additional system limit is used, install in series with the auxiliary limit jumper show

57D. System Controls and Wiring1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.2.

58Figure 30: System Wiring Schematic for Single Zone Space Heating Only

59Figure 31: Single Zone System with Packaged Alliance SL™ Water Heater Wiring SchematicNOTICEIf an additional system limit is used, install in serie

6Figure 2: Dimensions

60Figure 32: Circulator Zoned System Wiring Schematic

61Figure 33: Zone Valve Zoned System Wiring Schematic

62Figure 34: Different Manufacturer’s Zone Valve Connections to Honeywell R8889

63A. General Guidelines1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual

64Figure 35: Modular Boiler Gas Piping

65A. Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests spe

66Figure 36: Operating Instructions

67H. Operating Instructions.1. Follow Operating Instructions to place boiler in operation. See Figure 36.2. Enhanced Electronic Ignition Module wi

68TABLE 11: GREEN LED STATUS CODESGreen LED FlashCodeaIndicates Next System Action Recommended Service ActionOFF No “Call for Heat” N/A NoneFlash Fas

69Figure 38: Troubleshooting GuideHoneywell Electronic Ignition Troubleshooting Guide"CALL FOR HEAT."POWER TOMODULE? (24 VNOMINAL)NOYES30 S

7WARNINGIf you do not follow these instructions exactly, a re or explosion may result causing property damage or personal injury.DANGER

70I. Sequence of Operation. See Figure 39. If boiler fails to operate properly, see Troubleshooting Tree in Section IX: Service.J. Check pilot burn

71TABLE 13: GAS FLOW RATE IN CUBIC FEET PER HOURO. Check limit.1. Adjust thermostat to highest setting.2. Observe temperature gauge. When tem

72IX. ServiceA. General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or ma

73Figure 42: Silicone Tubing AssemblyFigure 43: Blower Vent Connector Assemblyd. Remove wires to Flame Roll-out Switch.e. Remove air diffuser scre

74Figure 44: Flue and Burner Cleanout, 1” Burner

75Figure 45: Differential Pressure MeasurementTABLE 15: DIFFERENTIAL PRESSURE SWITCH SETTINGSE. Main Burners and Firebox.1. Vacuum rebox. Exercis

76

77

78XI. Repair PartsAll SCG Repair Parts may be obtained through your local U.S. Boiler Wholesale distributor. Should you require assistance in locati

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

8c. 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

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

9III. Venting / Air Intake PipingTABLE 1: AIR INTAKE / VENT SYSTEM OPTIONSWARNINGDo not use this boiler with galvanized, Type 304 or Type 316 stainl

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

96Subject to the terms and conditions set forth below, U.S. Boiler Company, Inc. Lancaster, Pennsylvania hereby extends the following limited warranti