Burnham 1100-H4 manual

8140705R9-10/08 As an ENERGY ST AR ® Partner , Burnham Hydronics has determined that the SCG meets the ENERGY ST AR ® guidelines for energy ef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 L[...]

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 W ARNING This boiler requires regular maintenance and service to operate safely . Follow the instructions contained in this manual. Improper insta llation, adjust ment, alteratio n, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up oper[...]

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 Piping and T rim ................. 45 V . Gas Piping .................................... 50 VI. Electrical .....[...]

5 Figure 2: Dimensions[...]

6 W ARNING If you do not follow these instructions exactly , a re or explosion may result causing property damage or personal injury . DANGER Do not install boiler where gasoline or other ammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used or store[...]

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ned space. Use indoor air if two permanent openings communicate directly with additional space(s) of sufcient volume[...]

8 III. V enting / Air Intake Piping T ABLE 1: AIR INT AKE / VENT SYSTEM OPTIONS W ARNING Do not use this boiler with galvanized, T ype 304 or T ype 316 stainless steel, non metallic or any other non AL29-4C ® based vent systems. Do not use a barometric damper or drafthood with this appliance. Do not use vent dampers with this boiler . Moisture and[...]

9 T ABLE 3: BURNHAM VENT SYSTEM AND AIR INT AKE SYSTEM COMPONENTS T ABLE 2: VENT SYSTEM COMPONENTS INCLUDED WITH BOILER T ABLE 4: VENT/AIR INT AKE LENGTH V ent System Components Part Number Gasketed V ent T erminal 3” Horizontal (SCG-3 thru SCG-7) 81 10701 Gasketed V ent T erminal 4” Horizontal (SCG-8 & SCG 9) 81 10702 Disc Air Intake - 3?[...]

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[...]

1 1 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cally required by these instructions. The vent termination location is re[...]

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 4A: 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guration (SCG-3 thru 7)[...]

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

17 V ertical V enting – 1. See Figure 43 on Page 72 for Blower V ent Connector Assembly . Do not exceed maximum vent lengths. Refer to T able 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[...]

18 d. Install storm collar on air intake pipe immediately above 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, usi[...]

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 COMBINA TION HORIZONT AL VENT SYSTEM COMPONENTS F . Combination Horizontal V enting System –SCG-3 Through SCG-6 ONL Y – See Figures 10 and 1 1. 1. Do not exceed maximum vent/air intake lengths. Refer to T able 4. 2. Install Combination V ent/Air T erminal. See Figure 1 1. a. After determining the location with reference to Section B - Genera[...]

24 c. From exterior of building, insert air box sub- assembly into square opening. Push air box inward until wall 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 steel[...]

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 G. Combination V ertical V enting System – SCG-3 Thr ough SCG-6 ONL Y – See Figures 12, 13 and 14. NOTICE This vent system requires components not supplied with the boiler . Description Part Number SCG-3 & SCG-4 SCG-5 & SCG-6 V ent Carton Part Number 100222-01 100223-01 Air Intake T ee 100224-01 100225-01 T ermination Adapter 100226-[...]

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 nish. 2. As a Special Gas V ent system: Saf-T V e[...]

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 re resistance rating equal to or greater than that of the oor or roof assemblies through which it passes. • Design any enclos[...]

30 7. 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 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. (Unles[...]

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 ue exhaust collars. The male end of the tee connects to EZ Seal appliance adapters and the tee takeoff/snout connects to the[...]

33 1 1. 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 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 op[...]

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 1 1. 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 structure. Fire stop manufacturers are Air-Jet, American Metal Products, Metal-Fab, and Simpson Dura-V ent. 12. Whenever possible install vent straight through roof. Refer to Figure 6. Maintain[...]

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

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

40 Figure 15: Indoor Air - 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 - V ent T erminal Insta[...]

41 1. Do not exceed maximum vent/air intake lengths. Refer to T able 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. NOTICE Exterior run to be included in equivalent vent/air intake lengths. 3. Install[...]

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 ttings. c. Oxygen permeable materials in the di[...]

46 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 100592-01) into the plug of the SCG factory wiring. How to T est Shut off fuel supply . Lower water level until water level is BELOW the L WCO. Generate[...]

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 ow to maintain[...]

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 RA TINGS T ABLE 6: SPECIFIC GRA VITY CORRECTION F ACTORS FOR NA TURAL GAS W ARNING 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. An additiona[...]

51 T ABLE 7: MAXIMUM CAP ACITY OF SCHEDULE 40 PIPE IN CFH* FOR NA TURAL GAS PRESSURES OF 0.5 PSIG OR LESS Figure 27: Recommended Gas Piping T ABLE 8: EQUIV ALENT LENGTHS OF ST ANDARD PIPE FITTINGS & V AL VES B. Connect boiler gas valve to gas supply system. W ARNING Failure to use proper thread compounds on all gas connectors may result in leak[...]

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 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 , NFP A 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 de[...]

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

55 Figure 29: Internal Boiler Wiring Ladder Diagram NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below .[...]

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 NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below .[...]

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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 installed[...]

65 Figure 36: Operating Instructions[...]

66 H. Operating Instructions . 1. Follow Operating Instructions to place boiler in operation. See Figure 36. 2. Electronic Ignition Modules with LED indicators. T able 10 cross-references the ignition module terminal designations to the ignition terminal Figure 37: LED Locations Ignition Module T erminal Designation Wiring Ladder Diagram T erminal [...]

67 Green LED Flash Code (X + Y) a Indicates Next System Action Recommended Service Action OFF No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None 2 5 minute Retry Delay- Pilot ame not detected during trial for ignition Initiate new trial for ignition after retry delay complete[...]

68 Figure 38: T roubleshooting Guide Honeywell Electronic Ignition T roubleshooting Guide[...]

69 I. Sequence of Operation. See Figure 39. If boiler fails to operate properly , see T roubleshooting T ree in Section IX: Service. J. Check pilot burner ame. See Figure 41. Flame should be steady , medium hard blue enveloping 3/8 to ½ inch of sensing probe. K. Check main burner ame. See Figures 40. Flame should have clearly dened inner [...]

70 T ABLE 13: GAS FLOW RA TE 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. [...]

71 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 36. B. Low water cutoff (if so equipped). Probe T ype (Annual Service). Probe type L WCO should be removed once a year , exam[...]

72 Figure 42: Silicone T ubing Assembly Figure 43: 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ce. Burner which holds pilo[...]

73 Figure 44: Flue and Burner Cleanout, 1” Burner[...]

74 Figure 45: Differential Pressure Measurement T ABLE 15: DIFFERENTIAL PRESSURE SWITCH SETTINGS E. Main Burners and Firebox. 1. V acuum rebox. Exercise care - do not damage base insulation. 2. Clean main burners. Brush top of burners with soft bristle brush. See Figure 44. V acuum to remove any dirt and lint. 3. V acuum tip of pilot burner . 4.[...]

75 THIS P AGE LEFT INTENTIONALL Y BLANK[...]

76[...]

77[...]

78 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.[...]

79 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 1. CASTING ASSEMBL Y 1 Section Assembly 61707031 61707041 61707051 61707061 61707071 61707081 61707091 1A Left End Section 71707001 1B Center Section (1) 71707003 (2) 71707003 (3) 71707003 (4) 71707003 (5) 71707003 (6) 71707003 (7) 71707003 1C Right End Section [...]

80[...]

81 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 2. BASE ASSEMBL Y 2A Base Wrapper 71807 031 718070 41 71 807051 71807061 7 180707 1 71807081 71807091 2B Base T ray 71807 032 71807042 7 180 7052 7 1807062 718 07072 7180 7082 71807092 2C Burner T ray Assembly 61807 031 618070 41 61 807051 61807061 6 180707 1 61[...]

82[...]

83 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 2. BASE ENCLOSURE ASSEMBL Y 3A Air Box Assembly 61807032 61807042 61807052 61807 062 61807072 61807082 61807 092 3B Air Box Door 71807034 71807044 71807 054 71807064 71807074 718070 84 71807094 3C Combustion Air Diffuser N/A 71807049 71807059 71807 069 71807079 [...]

84[...]

85 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 4. F AN/CANOPY ASSEMBL Y 4A Canopy Assembly - Sea Level 61 107031 61 107041 61 107051 61 107061 61 107071 61 107081 61 107091 Canopy Assembly - High Altitude 61 107032 61 107042 61 107052 61 107062 61 107072 61 107082 61 107092 4B Cerafelt 9206005 4C U-Clip (4) [...]

86[...]

87 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 5. BURNER ASSEMBLIES 5A Gas V alve (Natural Gas), Honeywell VR8204P1 171 81660282 N/A Gas V alve (Natural Gas), Honeywell VR8304P4496 N/A 81660283 Gas V alve (LP Gas), Honeywell VR8204C3015 81660146 N/A Gas V alve (LP Gas), Honeywell VR8304P4280 N/A 81660160 5B [...]

88[...]

89 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 6. CONTROL P ANEL ASSEMBL Y 6A Limit, Honeywell L4080D 100189-01 6B T ransformer/Relay , Honeywell R8285D 80160155U 6C Ignition Module, Honeywell S8670E3003 100959-01 6D Blower Relay , Honeywell R8222U1006 80160096U 6E Differential Pressure Switch Sea Level 0’[...]

90[...]

91 Ke y No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 7. JACKET P ARTS 7A Jacket Left Side Panel 60407002 7B Jacket Right Side Panel 60407001 7C Rear Panel 60407033 60407043 60407053 60407063 60407073 60407083 60407093 7D V estibule Panel 60407034 60407044 60407054 60407064 60407074 60407084 60407094 7E T op Panel[...]

92 Ke y No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 8. MISCELLANEOUS P ARTS CARTON 8A W ater Manifold 80607001 8B T emperature/Pressure Gauge 8056169 8C Circulator Wiring Harness 6130701 8D Safety Relief V alve 81660363 8E Boiler Drain V alve 806603061 8F V ent T erminal 81 10701 81 10702 8G Air Intake T erminal[...]

93 Important Produc t Safety Informat ion Refractory Ceram ic Fiber Product Warning : The Repair Parts list designates parts that contain refracto ry ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, su ch as during direct flame contact, RCF changes into crystalline silica, a k[...]

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

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

96 79 water boiler for its intended purposes and its maintenance 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 bei[...]