Burnham SCG manual

8140705R3-1/07 As an ENERGY ST AR ® Partner , Burnham Hydronics has determined that the SCG meets the ENERGY ST AR ® guidelines for energy ef fi ciency established by the United States Environmental Protection Agency (EP A). Price - $5.00 D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S ™ G C S R E [...]

2 IMPOR T ANT INFORMA TION - READ CAREFULL Y NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. All wiring on b[...]

3 E C I T O N . l a u n a m s i h t f o k c a b e h t n o d e t n i r p s i h c i h w f o y p o c a , y t n a r r a w d e t i m i l a s a h r e l i o b s i h T d e l l a t s n i y l t c e r r o c e r a s l o r t n o c l l a t a h t e e s o t r o t c a r t n o c g n i l l a t s n i e h t f o y t i l i b i s n o p s e r e h t s i t I . e t e l p m o [...]

4 T able of Contents Figure 1: Minimum Clearances to Combustibles I. P re-Installation ............................... 6 II. U npack Boiler ................................ 7 III. V enting/Air I ntake Piping .............. 8 IV . W ater P iping and T rim ................. 45 V . Gas Piping .................................... 50 VI. Electrical ....[...]

5 Figure 2: Dimensions[...]

6 G N I N R A W s n o i t c u r t s n i e s e h t w o l l o f t o n o d u o y f I t l u s e r y a m n o i s o l p x e r o e r i f a , y l t c a x e l a n o s r e p r o e g a m a d y t r e p o r p g n i s u a c . y r u j n i R E G N A D r e h t o r o e n i l o s a g e r e h w r e l i o b l l a t s n i t o n o D f o s e c r u o s r o , s d i u q i l [...]

7 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. Alternate method for boiler located within con fi ned space. Use indoor air if two permanent openings communicate directly with additional space(s) of suf fi cient vo[...]

8 III. V enting / Air Intake Piping T able 1: Air Intake / V ent System Options G N I N R A W r o c i l l a t e m n o n , l e e t s s s e l n i a t s 6 1 3 e p y T r o 4 0 3 e p y T , d e z i n a v l a g h t i w r e l i o b s i h t e s u t o n o D C 4 - 9 2 L A n o n r e h t o y n a ® . s m e t s y s t n e v d e s a b . e c n a i l p p a s i h t h[...]

9 T able 3: Burnham V ent System and Air Intake System Components T able 2: V ent System Components Included with Boiler s t n e n o p m o C m e t s y S t n e Vr e b m u N t r a P " 3 l a n i m r e T t n e V d e t e k s a G ) 7 - G C S u r h t 3 - G C S ( l a t n o z i r o H 1 0 7 0 1 1 8 " 4 l a n i m r e T t n e V d e t e k s a G ) 9 G [...]

10 A. V ent Guidelines Due to Removal of an Existing Boiler 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 exist[...]

11 with at least one side open, similar to a joist bay application. Use double wall thimble [Burnham Part No. 81 16115 (3”), 100185-01 (4”)] when penetrating a combustible wall. 9. Do not install venting system components on the exterior of the building except as speci fi cally required by these instructions. The vent termination location is r[...]

12 a. W ipe 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 motion to FULL Y 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. V erify the factory- installed gasket is not d[...]

13 Figure 4: Recommended Separate Horizontal – V ent/Air Intake Installation[...]

14 Figure 4B: Alternate Separate Horizontal – V ent/Air Intake Installation[...]

15 Figure 5A: Separate Horizontal – V ent/Air Intake T erminal Con fi guration (SCG-3 thru 7)[...]

16 Figure 5B: Separate Horizontal – V ent/Air Intake T erminal Con fi guration (SCG-8 and 9)[...]

17 V ertical V enting – 1. Do not exceed maximum vent lengths. Refer to T able 4. 2. Installation of a vertical vent 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 . 3. Slope horizontal runs minimum [...]

18 d. Install storm collar on air intake pipe immediately above fl ashing. Apply Dow Corning Silastic 732 R TV Sealant between air intake pipe and storm collar to provide weathertight seal. e. All exposed air intake piping must be constructed of corrosion resistant material such as aluminum, stainless steel or PVC. 15. Seal all joints airtight, us[...]

19 Figure 7: Attic Offset Figure 6: V ertical V ent Installation[...]

20 Figure 8A: V ertical V ent/Air T ermination (3” V ent T erminal) Extend V ent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.[...]

21 Figure 8B: V ertical V ent/Air T ermination (4” V ent T erminal) Extend V ent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow ad- ditional vertical (“X”) distance for expected snow accumulation.[...]

22 Figure 9: V ertical Air Intake Piping[...]

23 F. Combination Horizontal V enting System –SCG-3 Through SCG-6 ONL Y – See Figures 10 and 1 1. E C I T O N t o n s t n e n o p m o c s e r i u q e r m e t s y s t n e v s i h T . r e l i o b e h t h t i w d e i l p p u s 1. Do not exceed maximum vent/air intake lengths. Refer to T able 4. 2. Install Combination V ent/Air T erminal. See Figur[...]

24 c. From exterior of building, insert air box sub- assembly into square opening. Push air box inward until wall fl ange 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. d. Drill four (4) pilot holes, properly sized for the non-corrosive fasteners (stainless stee[...]

25 Figure 10: Combination Horizontal – V ent/Air Installation (SCG-3 thru 6)[...]

26 Figure 1 1: Combination Horizontal – V ent/Air T erminal Installation (SCG-3 thru 6)[...]

27 n o i t p i r c s e D r e b m u N t r a P 4 - G C S & 3 - G C S6 - G C S & 5 - G C S r e b m u N t r a P n o t r a C t n e V 1 0 - 2 2 2 0 0 11 0 - 3 2 2 0 0 1 e e T r e t r a t S 1 0 - 4 2 2 0 0 11 0 - 5 2 2 0 0 1 r o t p a d A r i A / t n e V 1 0 - 6 2 2 0 0 1 S T N E N O P M O C M E T S Y S T N E V L A C I T R E V N O I T A N I B M O [...]

28 1. Saf-T V ent 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 fi nish. 2. As a Special Gas V ent system: Saf-T V [...]

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 dwellings), the vent system shall be enclosed with an enclosure having a fi re resistance rating equal to or greater than that of the fl oor or roof assemblies through which it passes. • Design any encl[...]

30 7. Joint Assembly Instructions: a. Before joining the sections or fi ttings 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 af fect the integrity of the seal. Install the system with the female ends (ends with the red seal) pointing away from the appliance. (Unle[...]

31 8. Straight Sections Cut T o Length: 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). b. Select a section that is lo[...]

32 9. Air Intake Connections for Dir ect V ent and Sealed Combustion Appliances*: The Air Intake T ee may be used on approved direct vent and sealed combustion appliances that have separate (non- concentric) air intake and fl ue exhaust collars. The male end of the tee connects to EZ Seal appliance adapters and the tee takeoff/snout connects to th[...]

33 11 . Horizontal Supports: Saf-T V ent 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 soli[...]

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 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 [...]

35 Fire Stop/W all Thimble/Support, (SC_ _FS): • The Saf-T V ent SC Fire Stop can be used as a fi restop, a wall thimble, or as a support plate. • T o use as a W all 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 o[...]

36 V ertical T erminations, (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 jac[...]

37 V ertical – 10. Installation of a vertical vent tee 81 16304U 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 . 1 1. Install fi re stops where vent passes through fl oors, ceilings or framed walls. The fi re stop m[...]

38 Figure 12: Recommended Separate Horizontal - V ent Installation[...]

39 Figure 13: Alternate Separate Horizontal - V ent Installation[...]

40 Figure 15: Indoor Air - Horizontal / V ertical V ent T erminal Installation Extend V ent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve (12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation. Figure 14: Optional Indoor Air - 3” or [...]

41 1. Do not exceed maximum vent/air intake lengths. Refer to T able 4. 2. This installation will allow a maximum of fi ve (5) feet vertical exterior run of the vent/air intake piping to be installed on separate horizontal venting and indoor air horizontal venting. E C I T O N t n e l a v i u q e n i d e d u l c n i e b o t n u r r o i r e t x E .[...]

42 Figure 18: Optional Separate Horizontal Air 5” Intake T erminal Installation Figure 19: Optional Separate Horizontal 3” V ent T erminal Installation[...]

43 Figure 20: Optional Separate Horizontal 4” V ent T erminal Installation Figure 21: Optional Separate Horizontal 3” V ent T erminal Installation (Indoor Air)[...]

44 Figure 22: Optional Separate Horizontal 4” V ent T erminal Installation (Indoor Air)[...]

45 A. Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system leaks. b. Absorption through open tanks and fi ttings. c. Oxygen permeable materials in the d[...]

46 draining the heating system. Many probe L WCO manufacturers recommend an annual inspection of the probe. How to W ire Ensure power is turned off to boiler . Locate the L WCO jumper wire in the factory wiring harness. Remove the jumper wire and install the L WCO wiring from L WCO Model 1 100-H4 (P/N 45-1 100) into the plug of the SCG factory wiri[...]

47 Figure 24: Supply W ater Manifold Piping Install pipe tee between circulator and boiler return 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 fl ow to maintai[...]

48 Figure 25: Recommended W ater Piping for Circulator Zoned Heating Systems[...]

49 Figure 26: Recommended W ater Piping for Zone V alve Zoned Heating Systems[...]

50 V . Gas Piping T able 5: Gas Ratings For materials or conditions other than those listed above, refer to National Fuel Gas Code , NFP A54/ANSI Z223.1, or size system using standard engineering methods acceptable to authority having jurisdiction. T able 6: Speci fi c Gravity Correction Factors G N I N R A W o t y l p p u s s a g e p i p y l r e [...]

51 T able 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Gas Pressures of 0.5 psig or Less Figure 27: Recommended Gas Piping T able 8: Equivalent Lengths of Standard Pipe Fittings & V alves B. Connect boiler gas valve to gas supply system. G N I N R A W n o s d n u o p m o c d a e r h t r e p o r p e s u o t e r u l i a F f o s k a e l n i[...]

52 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 , NFP A 70. C. Pressur e test. The boiler and its gas connection must be leak tested before placing boiler in operation. 1. Protect[...]

53 VI. Electrical G N I N R A W l a c i s y h p s u o i r e s n i t l u s e r y a m r e l i o b e h t o t s n o i t c e n n o c l a c i r t c e l e e r i w y l r e p o r p o t e r u l i a F . m r a h e r o f e b f f o s i r e w o p l l a e r u s e k a M . e c r u o s e n o n a h t e r o m m o r f e b y a m r e w o p l a c i r t c e l E . k r o w l [...]

54 Figure 28: Internal Boiler Wiring Schematic Diagram[...]

55 Figure 29: Internal Boiler Wiring Ladder Diagram E C I T O N e h t n i n w o h s r e p m u j t i m i l y r a i l i x u a e h t h t i w s e i r e s n i l l a t s n i , d e s u s i t i m i l m e t s y s l a n o i t i d d a n a f I . w o l e b g n i w a r d[...]

56 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[...]

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

58 Figure 31: Single Zone System with Packaged Alliance™ Water Heater W iring Schematic E C I T O N e h t n i n w o h s r e p m u j t i m i l y r a i l i x u a e h t h t i w s e i r e s n i l l a t s n i , d e s u s i t i m i l m e t s y s l a n o i t i d d a n a f I . w o l e b g n i w a r d[...]

59 Figure 32: Circulator Zoned System Wiring Schematic[...]

60 Figure 33: Zone V alve Zoned System Wiring Schematic[...]

61 Figure 34: Different Manufacturer ’ s Zone V alve Connections to Honeywell R8889[...]

62 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. 2. Consult Local Building Codes or National Fuel Gas Code, NFP A 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. B. Modu[...]

63 Figure 35: Modular Boiler Gas Piping[...]

64 A. Safe operation and other performance criteria were met with gas manifold and control assembly provided on boiler when boiler underwent tests speci fi ed in American National Standar d for Gas-Fired Low- Pr essure Steam and Hot W ater Boilers, ANSI Z21.13. B. V erify that the venting, water piping, gas piping and electrical system are install[...]

65 Figure 36: Operating Instructions[...]

66 Figure 38: 1 Inch Main Burner fl ame Figure 39: Pilot Burner Flame Figure 37: Sequence of Operation H. Follow Operating Instructions to place boiler in operation. See Figure 36. I. Sequence of Operation. See Figure 37. If boiler fails to operate properly , see T roubleshooting T ree in Section IX: Service. J. Check pilot burner fl ame. See Fig[...]

67 T able 10: Gas Flow Rate in Cubic Feet Per Hour O. Check limit. 1. Adjust thermostat to highest setting. 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. I[...]

68 IX. Service A. General. Inspection and service should be conducted annually . T urn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 37. B. Low water cutoff (if so equipped). Probe T ype (Annual Service). Probe type L WCO should be removed once a year , exam[...]

69 Figure 40: Silicone T ubing Assembly Figure 41: Blower V ent Connector Assembly 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 ori fi ce. Burner which holds pi[...]

70 Figure 42: Flue and Burner Cleanout, 1” Burner[...]

71 T able 1 1: Pilot Burner Location G. Procedur e for Measuring Differential Pr essure (See Figure 43). 1. With boiler of f, 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 [...]

72[...]

73[...]

74 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.[...]

75 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C S6 - G C S7 - G C S8 - G C S9 - G C S Y L B M E S S A G N I T S A C . 1 1y l b m e s s A n o i t c e S1 3 0 7 0 7 1 61 4 0 7 0 7 1 61 5 0 7 0 7 1 61 6 0 7 0 7 1 51 7 0 7 0 7 1 61 8 0 7 0 7 1 61 9 0 7 0 7 1 6 A 1n o i t c e S d n E t f e L 1 0 0 7 [...]

76[...]

77 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C S6 - G C S7 - G C S8 - G C S9 - G C S Y L B M E S S A E S A B . 2 A 2r e p p a r W e s a B1 3 0 7 0 8 1 71 4 0 7 0 8 1 71 5 0 7 0 8 1 71 6 0 7 0 8 1 71 7 0 7 0 8 1 71 8 0 7 0 8 1 71 9 0 7 0 8 1 7 B 2y a r T e s a B2 3 0 7 0 8 1 72 4 0 7 0 8 1 72 5[...]

78[...]

79 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C S6 - G C S7 - G C S8 - G C S9 - G C S Y L B M E S S A E R U S O L C N E E S A B . 3 A 3y l b m e s s A x o B r i A2 3 0 7 0 8 1 62 4 0 7 0 8 1 62 5 0 7 0 8 1 62 6 0 7 0 8 1 62 7 0 7 0 8 1 62 8 0 7 0 8 1 62 9 0 7 0 8 1 6 B 3r o o D x o B r i A4 3 0[...]

80[...]

81 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C SC S6 - GC S7 - GC S- G8 C S- G9 Y L B M E S S A Y P O N A C / N A F . 4 A 4 l e v e L a e S - y l b m e s s A y p o n a C1 3 0 7 0 1 1 61 4 0 7 0 1 1 61 5 0 7 0 1 1 61 6 0 7 0 1 1 61 7 0 7 0 1 1 61 8 0 7 0 1 1 61 9 0 7 0 1 1 6 e d u t i t l A h g[...]

82[...]

83 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C S 6 - G C S7 - G C S- G C S8 - G C S9 S E I L B M E S S A R E N R U B . 5 A 5 , ) s a G l a r u t a N ( e v l a V s a G 1 7 1 1 P 4 0 2 8 R V l l e w y e n o H 2 8 2 0 6 6 1 8A / N , ) s a G l a r u t a N ( e v l a V s a G 6 9 4 4 P 4 0 3 8 R V l [...]

84[...]

85 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C S6 - G C S7 - G C S8 - G C S9 - G C S Y L B M E S S A L E N A P L O R T N O C . 6 A 6D 0 8 0 4 L l l e w y e n o H , t i m i L 6 5 1 0 6 1 0 8 B 6D 5 8 2 8 R l l e w y e n o H , y a l e R / r e m r o f s n a r T U 5 5 1 0 6 1 0 8 C 6 l l e w y e n[...]

86[...]

87 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C S6 - G C S7 - G C S8 - G C S9 - G C S S T R A P T E K C A J . 7 A 7l e n a P e d i S t f e L t e k c a J 2 0 0 7 0 4 0 6 B 7l e n a P e d i S t h g i R t e k c a J 1 0 0 7 0 4 0 6 C 7l e n a P r a e R3 3 0 7 0 4 0 63 4 0 7 0 4 0 63 5 0 7 0 4 0 63 [...]

88 y e K . o N n o i t p i r c s e D r e b m u N t r a P ] y t i t n a u Q [ 3 - G C S4 - G C S5 - G C S6 - G C S7 - G C S8 - G C S9 - G C S 8. N O T R A C S T R A P S U O E N A L L E C S I M A 8d l o f i n a M r e t a W 1 0 0 7 0 6 0 8 B 8e g u a G e r u s s e r P / e r u t a r e p m e T 9 6 1 6 5 0 8 C 8s s e n r a H g n i r i W r o t a l u c r i[...]

89 n o i t a m r o f n I y t e f a S t c u d o r P t n a t r o p m I t c u d o r P r e b i F c i m a r e C y r o t c a r f e R W arning : This product contains refractory ceramic fi bers (RCF). RCF has been classi fi ed as a possible human carcinogen. After this product is fi red, RCF may , when exposed to extremely high temperature (>1800F),[...]

90 SER VICE RECORD DA TE SERVICE PERFORMED[...]

91 SER VICE RECORD DA TE SERVICE PERFORMED[...]

w a ter b oiler for it s intended p u rpo s e s a nd it s m a inten a nce a ccord a nce with U. S . Boiler Co., Inc. recommend a tion s a nd hydronic s ind us try s t a nd a rd s . The s e w a rr a ntie s will b e in a pplic ab le if the re s identi a l gr a de w a ter b oiler i s us ed or oper a ted over it s r a ted c a p a city, i s sub jected t[...]