Burnham SCG 8140705R3 User Manual To The 3448b391 F5b2 4bef 99d9 F52b89ac44dd
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IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR S C G™ G A S - F I R E D BO I L E R 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). F o r s e r vi c e o r r e p a i r s to b o i le r, c a ll yo ur he a ti ng c o ntr a c to r. W he n s e e k i ng i nfo r m a ti o n o n b o i le r, p r o vi d e B o i le r M o d e l Num b e r a nd S e r i a l Num b e r a s s ho wn o n Ra ti ng L a b e l. B o i le r M o d e l Num b e r SCG _ _ _ _ - _ _ _ He a ti ng C o ntr a c to r B o i le r S e r i a l Num b e r Ins ta lla ti o n D a te _ _ _ _ _ _ _ _ P ho ne Num b e r A d d re s s 8140705R3-1/07 Price - $5.00 IMPORTANT INFORMATION - READ CAREFULLY 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 boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations. The New York City Department of Buildings has approved the SCG™ Series boiler: Approval No. MEA 5-06-E. The City of New York requires either a Licensed Master Plumber or a Fire Suppression Piping Contractor supervise the installation of this product. The Massachusetts Board of Plumbers and Gas Fitters has approved the SCG™ Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative. The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter. The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. D AN G E R C AU T I O N In d ic a t e s a n im m in e n t ly h a z a r d o u s s it u a t io n w h ic h , if n o t a v o id e d , w ill r e s u lt in d e a t h , s e r io u s in ju r y o r s u b s t a n t ia l p r o p e r t y d a ma g e . In d ic a t e s a p o t e n t ia lly h a z a r d o u s s it u a t io n w h ic h , if n o t a v o id e d , m a y r e s u lt in m o d e r a t e o r m in o r in ju r y o r p r o p e r t y d a ma g e . WAR N IN G N OT IC E In d ic a t e s a p o t e n t ia lly h a z a r d o u s s it u a t io n w h ic h , if n o t a v o id e d , c o u ld r e s u lt in d e a t h , s e r io u s in ju r y o r s u b s t a n t ia l p r o p e r t y d a ma g e . In d ic a t e s s p e c ia l in s t r u c t io n s o n in s t a lla t io n , o p e r a t io n , o r m a in t e n a n c e w h ic h a r e im p o r t a n t b u t n o t r e la t e d t o p e r s o n a l in ju r y h a z a r d s . D AN G E R D O N OT s t o r e o r u s e g a s o lin e o r o t h e r fla m m a b le v a p o r s o r liq u id s in t h e v ic in it y o f t h is o r a n y o t h e r a p p lia n c e . If y o u s m e ll g a s v a p o r s , D O N OT t r y t o o p e r a t e a n y a p p lia n c e - D O N OT t o u c h a n y e le c t r ic a l s w itc h o r u s e a n y p h o n e in th e b u ild in g . Im m e d ia te ly, c a ll th e g a s s u p p lie r fr o m a r e m o te ly lo c a t e d p h o n e . F o llo w t h e g a s s u p p lie r ' s in s t r u c t io n s o r if t h e s u p p lie r is u n a v a ila b le , c o n t a c t t h e fir e d e p a r t m e n t . 2 WAR N IN G T h is b o ile r r e q u ir e s r e g u la r m a in te n a n c e a n d s e r v ic e to o p e r a te s a fe ly. F o llo w th e in s t r u c t io n s c o n t a in e d in t h is m a n u a l. Im p r o p e r in s t a lla t io n , a d ju s t m e n t , a lt e r a t io n , s e r v ic e o r m a in t e n a n c e c a n c a u s e p r o p e r t y d a m a g e , p e r s o n a l in ju r y o r lo s s o f lif e . R e a d a n d u n d e r s t a n d t h e e n t ir e m a n u a l b e f o r e a t t e m p t in g in s t a lla t io n , s t a r t - u p o p e r a t io n , o r s e r v ic e . In s t a lla t io n a n d s e r v ic e m u s t b e p e r fo r m e d o n ly b y a n e x p e r ie n c e d , s k ille d , a n d k n o w le d g e a b le in s ta lle r o r s e r v ic e a g e n c y. T h is b o ile r m u s t b e p r o p e r ly v e n t e d . T h is b o ile r n e e d s f r e s h a ir fo r s a fe o p e r a t io n a n d m u s t b e in s t a lle d s o t h e r e a r e p r o v is io n s fo r a d e q u a te c o m b u s tio n a n d v e n tila tio n a ir. T h e in t e r io r o f t h e v e n t in g s y s t e m m u s t b e in s p e c t e d a n d c le a n e d b e fo r e t h e s t a r t o f t h e h e a t in g s e a s o n a n d s h o u ld b e in s p e c t e d p e r io d ic a lly t h r o u g h o u t t h e h e a t in g s e a s o n fo r a n y o b s t r u c t io n s . A c le a n a n d u n o b s t r u c t e d v e n t in g s y s t e m is n e c e s s a r y t o a llo w n o x io u s f u m e s t h a t c o u ld c a u s e in ju r y o r lo s s o f lif e t o v e n t s a f e ly a n d w ill c o n t r ib u t e t o w a r d m a in ta in in g th e b o ile r ' s e ffic ie n c y. In s t a lla t io n is n o t c o m p le t e u n le s s a p r e s s u r e r e lie f v a lv e is in s t a lle d in t o t h e t a p p in g lo c a te d o n to p o f a p p lia n c e . - S e e th e Wa te r P ip in g a n d Tr im S e c tio n o f th is m a n u a l fo r d e t a ils . T h is b o ile r is s u p p lie d w it h s a fe t y d e v ic e s w h ic h m a y c a u s e t h e b o ile r t o s h u t d o w n a n d n o t r e -s ta r t w ith o u t s e r v ic e . If d a m a g e d u e to fr o z e n p ip e s is a p o s s ib ility, th e h e a tin g s y s te m s h o u ld n o t b e le ft u n a t t e n d e d in c o ld w e a t h e r ; o r a p p r o p r ia t e s a fe g u a r d s a n d a la r m s s h o u ld b e in s t a lle d o n t h e h e a t in g s y s t e m t o p r e v e n t d a m a g e if t h e b o ile r is in o p e r a t iv e . T h is b o ile r c o n t a in s v e r y h o t w a t e r u n d e r h ig h p r e s s u r e . D o n o t u n s c r e w a n y p ip e fit t in g s n o r a t t e m p t t o d is c o n n e c t a n y c o m p o n e n t s o f t h is b o ile r w it h o u t p o s it iv e ly a s s u r in g t h e w a t e r i s c o o l a n d h a s n o p r e s s u r e . Al w a y s w e a r p r o t e c t i v e c l o t h i n g a n d e q u i p m e n t w h e n in s t a llin g , s t a r t in g u p o r s e r v ic in g t h is b o ile r t o p r e v e n t s c a ld in ju r ie s . D o n o t r e ly o n t h e p r e s s u r e a n d te m p e r a tu r e g a u g e s to d e te r m in e th e te m p e r a tu r e a n d p r e s s u r e o f th e b o ile r. T h is b o ile r c o n t a in s c o m p o n e n t s w h ic h b e c o m e v e r y h o t w h e n t h e b o ile r is o p e r a t in g . D o n o t t o u c h a n y c o m p o n e n t s u n le s s t h e y a r e c o o l. B o ile r m a t e r ia ls o f c o n s t r u c t io n , p r o d u c t s o f c o m b u s t io n a n d t h e fu e l c o n t a in a lu m in a , s ilic a , h e a v y m e t a ls , c a r b o n m o n o x id e , n it r o g e n o x id e s , a ld e h y d e s a n d /o r o t h e r t o x ic o r h a r m f u l s u b s t a n c e s w h ic h c a n c a u s e d e a t h o r s e r io u s in ju r y a n d w h ic h a r e k n o w n t o t h e s t a t e o f C a lifo r n ia to c a u s e c a n c e r, b ir th d e fe c ts a n d o th e r r e p r o d u c tiv e h a r m . Alw a y s u s e p r o p e r s a fe t y c lo t h in g , r e s p ir a t o r s a n d e q u ip m e n t w h e n s e r v ic in g o r w o r k in g n e a r b y t h e a p p lia n c e . F a ilu r e t o f o llo w a ll in s t r u c t io n s in t h e p r o p e r o r d e r c a n c a u s e p e r s o n a l in ju r y o r d e a t h . R e a d a ll in s t r u c t io n s , in c lu d in g a ll t h o s e c o n t a in e d in c o m p o n e n t m a n u fa c t u r e r s m a n u a ls w h ic h a r e p r o v id e d w it h t h e b o ile r b e fo r e in s t a llin g , s t a r t in g u p , o p e r a t in g , m a in t a in in g o r s e r v ic in g . K e e p b o ile r a r e a c le a r a n d fr e e fr o m c o m b u s t ib le m a t e r ia ls , g a s o lin e a n d o t h e r fla m m a b le v a p o r s o r liq u id s . Al l c o v e r p l a t e s , e n c l o s u r e s a n d g u a r d s m u s t b e i n p l a c e a t a l l t i m e s . N OT IC E T h is b o ile r h a s a lim ite d w a r r a n ty, a c o p y o f w h ic h is p r in te d o n th e b a c k o f th is m a n u a l. It is t h e r e s p o n s ib ilit y o f t h e in s t a llin g c o n t r a c t o r t o s e e t h a t a ll c o n t r o ls a r e c o r r e c t ly in s t a lle d a n d a r e o p e r a t in g p r o p e r ly w h e n t h e in s t a lla t io n is c o m p le t e . 3 Table of Contents I. Pre-Installation ............................... 6 VI. Electrical....................................... 53 II. Unpack Boiler ................................ 7 VII. Modular Installation .................... 62 III. Venting/Air Intake Piping .............. 8 VIII. System Start-up ............................ 64 IV. Water Piping and Trim ................. 45 IX. Service .......................................... 68 V. Gas Piping .................................... 50 X. Repair Parts .................................. 74 Figure 1: Minimum Clearances to Combustibles 4 5 Figure 2: Dimensions I. Pre-Installation WAR N IN G If y o u d o n o t fo llo w t h e s e in s t r u c t io n s e x a c tly, a fir e o r e x p lo s io n m a y r e s u lt c a u s in g p r o p e r t y d a m a g e o r p e r s o n a l in ju r y. D AN G E R D o n o t in s t a ll b o ile r w h e r e g a s o lin e o r o t h e r fla m m a b le v a p o r s o r liq u id s , o r s o u r c e s o f h y d r o c a r b o n s ( i.e . b le a c h e s , c le a n e r s , c h e m ic a ls , s p r a y s , p a in t r e m o v e r s , fa b r ic s o ft e n e r s , e t c .) a r e u s e d o r s t o r e d . N OT IC E D u e to th e lo w w a te r c o n te n t o f th e b o ile r, m is - s iz in g o f t h e b o ile r w it h r e g a r d t o t h e h e a t in g s y s t e m lo a d w ill r e s u lt in e x c e s s iv e b o ile r c y c lin g a n d a c c e le r a t e d c o m p o n e n t fa ilu r e . B u r n h a m D OE S N OT w a r r a n t fa ilu r e s c a u s e d b y m is - s iz e d b o ile r a p p lic a t io n s . D O N OT o v e r s iz e t h e b o ile r t o t h e s y s t e m . M o d u la r b o ile r in s t a lla t io n s g r e a t ly r e d u c e t h e lik e lih o o d o f b o ile r o v e r s iz in g . 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/ CGA B149 Installation Codes. B. Appliance is design certified for installation on combustible flooring. Do not install boiler on carpeting. 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. 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. E. Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.). 6 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 Installation Code, CAN/ CGA-B149.1, or Propane Installation Code, CAN/ CGA-B149.2, Venting Systems and Air Supply for Appliances. WAR N IN G Ad e q u a t e c o m b u s t i o n a n d v e n t i l a t i o n a i r m u s t b e p r o v id e d t o a s s u r e p r o p e r c o m b u s t io n . 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. 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. 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: 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; 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. 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. 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 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. 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. N OT IC E B o ile r s o p e r a t e d w it h d ir e c t v e n t ( s e a le d c o m b u s t io n ) a r e e x e m p t fr o m n e e d in g p r o v is io n s fo r c o m b u s t io n a ir fr o m t h e r o o m , p r o v id e d a ir in t a k e p ip in g is in s t a lle d p e r c o d e a n d t h e in s t r u c t io n s in t h is m a n u a l. 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: 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. 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. 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. CAUTION If u s in g in d o o r a ir fo r c o mb u s tio n (s e e Ve n tin g S e c tio n - In d o o r Air), a v o id o p e ra tin g th is b o ile r in a n e n v ir o n m e n t w h e r e s a w d u s t , lo o s e in s u la t io n f ib e r s , d r y w a ll d u s t , e t c . a r e p r e s e n t . If b o ile r is o p e r a t e d u n d e r t h e s e c o n d it io n s , t h e b u r n e r in t e r io r a n d p o r t s m u s t b e c le a n e d a n d in s p e c t e d d a ily t o in s u r e p r o p e r o p e r a t io n . II. Unpack Boiler C AU T ION D o n o t d r o p b o ile r. D o n o t b u m p b o ile r ja c k e t a g a in s t flo o r. A. Move boiler to approximate installed position. B. Remove all crate fasteners. C. Lift and remove outside container. Save two of the wooden slats from the container sleeve for use in Steps E and F. D. Remove all boiler hold-down fasteners. WAR N IN G In s t a lla t io n o f t h is b o ile r s h o u ld b e u n d e r t a k e n o n ly b y t r a in e d a n d s k ille d p e r s o n n e l fr o m a q u a lifie d s e r v ic e a g e n c y. E. Tilt the boiler to its front side or back side and slide a wooden slat under the three raised feet. 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 wooden slats as runners. H. Move boiler to its permanent location. 7 III. Venting / Air Intake Piping WAR N IN G D o n o t u s e t h i s b o i l e r w i t h g a l v a n i z e d , Ty p e 3 0 4 o r Ty p e 3 1 6 s t a i n l e s s s t e e l , n o n m e t a l l i c o r a n y o t h e r n o n AL 2 9 - 4 C ® b a s e d v e n t s y s t e m s . D o n o t u s e a b a r o m e t r ic d a m p e r o r d r a ft h o o d w it h t h is a p p lia n c e . D o n o t u s e v e n t d a m p e r s w ith th is b o ile r. M o i s t u r e a n d i c e m a y f o r m o n s u r f a c e s a r o u n d t e r m i n a t i o n . To p r e v e n t d e t e r i o r a t i o n , s u r fa c e s s h o u ld b e in g o o d r e p a ir ( s e a le d , p a in t e d , e t c .) . T h is a p p lia n c e n e e d s fr e s h a ir fo r s a fe o p e r a t io n a n d m u s t b e in s t a lle d s o t h e r e a r e p r o v is io n s fo r a d e q u a te c o m b u s tio n a n d v e n tila tio n a ir. D o n o t r e d u c e s iz e o f a ir in t a k e p ip e . R e a d , u n d e r s t a n d a n d fo llo w c o m b u s t io n a ir in s t r u c t io n r e s t r ic t io n s c o n t a in e d in t h e P r e In s t a lla t io n in s t r u c t io n s o f t h is m a n u a l. D o n o t o p e r a t e a p p lia n c e w h e r e g a s o lin e o r o t h e r fla m m a b le v a p o r s o r liq u id s , o r s o u r c e s o f h y d r o c a r b o n s ( i.e . b le a c h e s , c le a n e r s , c h e m ic a ls , s p r a y s , p a in t r e m o v e r s , fa b r ic s o ft e n e r s , e tc .) a r e u s e d , s to r e d a n d /o r p r e s e n t in th e a ir. W h e n in s ta llin g v e n t p ip e th r o u g h c h im n e y, n o o th e r a p p lia n c e c a n b e v e n te d in to th e c h im n e y. D o n o t e x c e e d m a x i m u m v e n t / a i r i n t a k e l e n g t h s . R e f e r t o Ta b l e 4 . Table 1: Air Intake / Vent System Options D e s c r i p ti o n A d d i ti o na l Ve nt K i t Re q ui r e d P a rt Num b e r Ins ta lla ti o n D r a wi ng a nd Sp e c i f i c a t i o n ( S e e S e c ti o n) 1 . S e p a r a te Ho ri zo nta l D i re c t Ve nt ( s e a le d c o m b us ti o n) wi th b o th the ve nt p i p e a nd a i r i nta k e p i p e te rm i na ti ng ho ri zo nta lly ( thro ug h a s i d e wa ll) wi th i nd i vi d ua l p e ne tra ti o ns fo r the ve nt a nd a i r i nta k e p i p i ng a nd te rm i na ls . No See Ta b le 2 D. 2 . S e p a r a te Ve r t i c a l D i re c t Ve nt ( s e a le d c o m b us ti o n) wi th b o th the ve nt p i p e a nd a i r i nta k e p i p e te rm i na ti ng ve rti c a lly ( thro ug h the ro o f) wi th i nd i vi d ua l p e ne tra ti o ns fo r the ve nt a nd a i r i nta k e p i p i ng a nd te rm i na ls . No See Ta b le 2 E. D i re c t Ve nt ( s e a le d c o m b us ti o n) wi th the ve nt p i p e 3 . C o m b i na ti o n a nd a i r i nta k e p i p e jo i ni ng a t a c o m m o n te rm i na l Ho ri zo nta l a nd te rm i na ti ng ho ri zo nta lly ( thro ug h a s i d e wa ll up to 1 5 " thi c k ) wi th o nly o ne p e ne tra ti o n. Ye s 3 - 6 S e c ti o n ( 6 11 0 6 0 1 2 ) F. Ye s 3 - 4 S e c ti o n (1 0 0 2 2 2 -0 1 ) 5 - 6 S e c ti o n (1 0 0 2 2 3 -0 1 ) G. Op ti o n D i re c t Ve nt ( s e a le d c o m b us ti o n) wi th the ve nt p i p e 4 . C o m b i na ti o n a nd a i r i nta k e p i p e jo i ni ng a t a c o m m o n te rm i na l a nd te rm i na ti ng ve rti c a lly ( thro ug h the ro o f) wi th Ve r t i c a l o nly o ne p e ne tra ti o n. 5 . Ind o o r A i r P o we r Ve nt - A i r us e d fo r c o m b us ti o n i s p ro vi d e d fro m wi thi n the b ui ld i ng . No S e e Ta b le 2 H. 6 . Op ti o na l S e p a r a te Ho ri zo nta l D i re c t Ve nt ( s e a le d c o m b us ti o n) wi th b o th the ve nt p i p e a nd a i r i nta k e p i p e te rm i na ti ng ho ri zo nta lly ( thro ug h a s i d e wa ll) wi th i nd i vi d ua l p e ne tra ti o ns fo r the ve nt a nd a i r i nta k e p i p i ng a nd te rm i na ls . No S e e Ta b le 2 I. 8 Table 2: Vent System Components Included with Boiler Ve nt S ys te m C o m p o ne nts P a r t Num b e r Ga s k e te d Ve nt Te rm i na l 3 " Ho ri zo nta l ( S C G-3 thru S C G-7 ) 8 11 0 7 0 1 Ga s k e te d Ve nt Te rm i na l 4 " Ho ri zo nta l ( S C G-8 & S C G 9 ) 8 11 0 7 0 2 D i s c A i r Inta k e - 3 " ( S C G- 3 & S C G- 4 ) 6 11 6 0 4 5 D i s c A i r Inta k e - 4 " ( S C G- 5 & S C G- 6 ) 6 11 6 0 4 9 A i r Inta k e - 5 " ( S C G-7 thru S C G-9 ) 6 11 6 0 6 3 Table 3: Burnham Vent System and Air Intake System Components Ve nt S ys te m C o m p o ne nt P a rt Num b e r E q ui va le nt Feet of Pi pe 3" D i a. Pi pe x 1 Ft 8 11 6 2 9 6 U 4" D i a. Pi pe x 1 Ft 1 0 0 1 7 6 -0 1 3" D i a. Pi pe x 3 Ft 8 11 6 2 9 8 U 4" D i a. Pi pe x 3 Ft 1 0 0 1 7 7 -0 1 3" D i a. Pi pe x 5 Ft 8 11 6 3 0 0 U 4" D i a. Pi pe x 5 Ft 1 0 0 1 7 8 -0 1 3 " D i a . P i p e x A d jus ta b le 8 11 6 3 1 9 U 4 " D i a . P i p e x A d jus ta b le 1 0 0 1 7 9 -0 1 3 " D i a . 9 0 ° E lb o w 8 11 6 2 9 4 U 4 " D i a . 9 0 ° E lb o w 1 0 0 1 8 0 -0 1 3 " D i a . 4 5 ° E lb o w 8 11 6 2 9 2 U 4 " D i a . 4 5 ° E lb o w 1 0 0 1 8 1 -0 1 3 " D i a . Ho ri zo nta l D ra i n Te e 8166302U 4 " D i a . Ho ri zo nta l D ra i n Te e 1 0 0 1 8 2 -0 1 3 " D i a . Ve rti c a l D ra i n Te e 8 11 6 3 0 4 U 4 " D i a . Ve rti c a l D ra i n Te e 1 0 0 1 8 3 -0 1 3 " S i ng le Wa ll Thi m b le 8 11 6 11 6 4 " S i ng le Wa ll Thi m b le 1 0 0 1 8 4 -0 1 3 " D o ub le Wa ll Thi m b le 8 11 6 11 5 4 " D o ub le Wa ll Thi m b le 1 0 0 1 8 5 -0 1 1 3 5 * * E q ua l to Ins ta lle d L e ng th ( 1 .0 6 to 1 .6 4 ) 5 Inta k e S ys te m C o m p o ne nts ( P a r ts b y Othe r s ) E q ui va le nt Feet of Pi pe * 3 " , 4 " , o r 5 " ID P i p e x 1 F t 1 3 " , 4 " , o r 5 " ID P i p e x 2 F t 2 3 " , 4 " , o r 5 " ID P i p e x 4 F t 4 3 " , 4 " , o r 5 " ID P i p e x 5 F t 5 3 " , o r 4 " 9 0 ° E lb o w 5 3 " , o r 4 " 4 5 ° E lb o w 5 5 " 9 0 ° E lb o w 6 5 " 4 5 ° E lb o w 6 5 7½ * E q ui va le nt F e e t o f P i p e B a s e d o n Sta nd a rd 4 " S m o k e P i p e D e s i g n 7½ --- --- Table 4: Vent/Air Intake Length Mo d e l 3 " A i r Inta k e P i p e 4 " A i r Inta k e P i p e 5 " A i r Inta k e P i p e ( E q ui v. F t.) ( E q ui v. F t.) ( E q ui v. F t.) 3 " Ve nt P i p e ( E q ui v. F t.) 4 " Ve nt P i p e ( E q ui v. F t.) M i n. M a x. M i n. M a x. M i n. M a x. M i n. M a x. M i n. M a x. S C G- 3 & S C G- 4 8 50 ---- ---- ---- ---- 8 50 ---- ---- S C G- 5 & S C G- 6 ---- ---- 8 50 ---- ---- 8 50 ---- ---- S C G- 7 ---- ---- ---- ---- 8 50 8 50 ---- ---- S C G- 8 & S C G- 9 ---- ---- ---- ---- 8 40 ---- ---- 8 40 9 A. Vent 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 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: 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. 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. 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. 10 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. 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. 3. Refer to the appropriate drawings in this section of this manual to determine the proper configuration of venting system. See Table 1. 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, Flex-L International Inc. - Star-34, Z-Flex U. S., Inc. Z-Vent, and Protech Systems , Inc.- FasNSeal™ 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. 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 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. 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: 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. 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. e. Minimum twelve (12) inches from overhang or corner of building. 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. Note: For one or two family dwellings, fire resistance rating requirement may not need to be met, but is recommended. 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. 12. Once a vent pipe manufacturer and system is chosen never mix and match vent systems. 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 GasketLess Vent System. WARNING N e v e r e x c e e d m a x im u m in s t a lle d le n g t h o f 1 9 ¾ i n c h e s f o r a d ju s t a b l e l e n g t h p i p e . R is k o f f lu e g a s le a k a g e is p o s s ib le . N OT IC E C u t m u s t b e s q u a r e w it h p ip e a n d file d o r s a n d e d s m o o t h b e f o r e jo in in g . C a r e f u lly e n s u r e r o u n d n e s s o f c u t p ip e b y h a n d w it h g lo v e s b e f o r e in s t a llin g . S e a l jo in t w it h R T V s p e c ifie d in t h is m a n u a l. C. Install Vent Pipe, Burnham Gasketed Vent System. 1. Procedure for Joining Burnham Gasketed Vent Pipe and Fittings. See Figure 3. Figure 3: Burnham Gasketed Vent Joint Detail 11 a. 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 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 factoryinstalled gasket is not dislodged or cut. 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! d. Once the installation is complete, operate appliance and inspect all joints to ensure that flue gases and/or liquid condensate will not escape. D. Separate Horizontal Venting System. See Figures 4, 5A and 5B. Vent Piping – 1. This boiler is supplied with components as standard equipment for installation of the separate horizontal venting system. 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 4. 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. 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. Air Intake piping - See Figures 4, 5A and 5B. 12 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. 9. Do not exceed air intake length. See Table 4. 10. Use single wall metal or PVC pipe. 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. 11. Air intake termination must be located: Horizontal - At least twelve (12) inches above grade plus the expected snow accumulation. 12. Start at collar on burner enclosure (inside boiler jacket) and work towards the air intake terminal. 13. Maintain minimum of ¼ inch per foot slope on horizontal runs. Slope towards air inlet terminal when possible. If not, slope towards boiler. 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. 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. 16. Seal all joints airtight, using silicone caulk or selfadhesive 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. 13 Figure 4: Recommended Separate Horizontal – Vent/Air Intake Installation 14 Figure 4B: Alternate Separate Horizontal – Vent/Air Intake Installation 15 Figure 5A: Separate Horizontal – Vent/Air Intake Terminal Configuration (SCG-3 thru 7) 16 Figure 5B: Separate Horizontal – Vent/Air Intake Terminal Configuration (SCG-8 and 9) E. Separate Vertical Venting System - See Figures 6, 7, 8A, 8B and 9. N OT IC E R o o f p e n e t r a t io n s r e q u ir e t h e u s e o f r o o f fla s h in g a n d s t o r m c o lla r - n o t s u p p lie d w it h b o ile r. Vertical Venting – 1. Do not exceed maximum vent lengths. Refer to Table 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 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. 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. 5. Whenever possible, install vent straight through the roof. Refer to Figure 7 if offset is necessary. Maintain minimum clearance to combustible materials. 6. Install Vent Terminal. 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. N OT IC E Ve r t i c a l v e n t i n g r e q u i r e s t h e u s e o f r o o f fla s h in g a n d a s t o r m c o lla r t o p r e v e n t m o is t u r e fr o m e n t e r in g t h e s t r u c t u r e . 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. d. Attach vent terminal. Vertical Air Intake Piping – 7. Do not exceed maximum air intake length. Refer to Table 4. 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. 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. 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: 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. 12. Maintain minimum of ¼ inch per foot slope on horizontal runs. Slope down towards boiler. 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. 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 AirJet, American Metal Products, Metal Fab, and Simpson Dura-Vent. 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. c. Vertical air intake requires flashing and a storm collar to prevent moisture from entering the structure. 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. e. All exposed air intake piping must be constructed of corrosion resistant material such as aluminum, stainless steel or PVC. 18 15. Seal all joints airtight, using silicone caulk or selfadhesive 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. 19 Figure 6: Vertical Vent Installation Figure 7: Attic Offset 20 Extend Vent/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 8A: Vertical Vent/Air Termination (3” Vent Terminal) 21 Extend Vent/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 8B: Vertical Vent/Air Termination (4” Vent Terminal) Figure 9: Vertical Air Intake Piping 22 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. N OT IC E T h is v e n t s y s t e m r e q u ir e s c o m p o n e n t s n o t s u p p lie d w ith th e b o ile r. 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. Ve nt C a r to n P a r t Num b e r 6 11 0 6 0 1 2 ( i nc lud e s i te m s b e lo w) D e s c r i p ti o n C o m p o ne nt P a r t Num b e r A A i r B o x S ub -A s s e m b ly ( 6 " s q ua re x 2 ' lo ng ) 6 11 0 6 0 11 B E xte ri o r Wa ll C o ve r ( 1 0 " s q ua re ) 7 11 0 6 0 1 6 C 4 " x 3 " Ve nt P i p e Re d uc e r D P la te -S e a l E xte ri o r C o ve r ( 2 ) 7 11 0 6 0 1 7 E # 8 x ½" Sta i nle s s Ste e l S he e t M e ta l S c re w ( 1 9 ) 80860047 F # 1 0 - 3 2 x ¼" Sta i nle s s Ste e l M a c hi ne S c re w ( 8 ) 80860842 G # 1 0 - 3 2 x ½" A lum i num Sp a c e r ( 4 ) 80861617 8 11 6 2 3 9 C OM B INATION HORIZONTA L VE NT S YS TE M C OM P ONE NTS 23 c. From exterior of building, insert air box subassembly 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. 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.) 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.) 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. g. Reinstall air box sub-assembly into opening in exterior wall and secure to wall. WAR N IN G N o n - c o r r o s iv e fa s t e n e r s m u s t b e u s e d . 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. 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.) j. Secure end panel to air box sub-assembly with shipping screw and thirteen (13) number 8 sheet metal screws provided. 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. 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. 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). 24 3. Install Vent Piping. See Figure 10 and 11. a. Start at vent connector on boiler 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. 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. d. Use 3/4 inch pipe strap to support horizontal runs and maintain vent location and slope. Maximum support spacing is five (5) feet. 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. f. Connect vent piping to combination vent/air terminal. See Figure 10. 4. Install Air Intake Piping. See Figures 10 and 11. a. Do not exceed air intake length. See Table 4. 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. d. Start at collar on burner enclosure (inside boiler jacket) and work towards the combination vent/ air terminal. e. Maintain minimum of 1/4 inch per foot slope on horizontal runs. Slope down towards boiler. 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. 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). h. Seal all joints airtight, using silicone caulk or self-adhesive aluminum tape. 25 Figure 10: Combination Horizontal – Vent/Air Installation (SCG-3 thru 6) 26 Figure 11: Combination Horizontal – Vent/Air Terminal Installation (SCG-3 thru 6) G. Combination Vertical Venting System – SCG-3 Through SCG-6 ONLY – See Figures 12, 13 and 14. N OT IC E T h is v e n t s y s t e m r e q u ir e s c o m p o n e n t s n o t s u p p lie d w ith th e b o ile r. P a r t Num b e r D e s c r i p ti o n S C G- 3 & S C G- 4 S C G- 5 & S C G- 6 Ve nt C a r to n P a r t Num b e r 1 0 0 2 2 2 -0 1 1 0 0 2 2 3 -0 1 Sta r te r Te e 1 0 0 2 2 4 -0 1 1 0 0 2 2 5 -0 1 Ve nt/A i r A d a p to r 1 0 0 2 2 6 -0 1 C OM B INATION V E RTIC A L V E NT S YS TE M C OM P ONE NTS 27 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: • 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. • • • 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. • • For applications up to 550°F/288°C, approved sealants include GE RTV 106 and Dow Corning 736. • 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 maintain the required straight-line pitch and hold • 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. 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. 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. 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 flameproofed, fire-retardant, or plastered. (Source: NPFPA54/ANSI Z223.1-1999.) 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: NPFPA54/ ANSI Z223.1-1999.) Clearances to Combustibles: D i a m e te r C le a ra nc e to Ma xi mum F lue C o mb us ti b le Ori e nta ti o n Ga s Te mp . (°F ) M a te r i a l 550 0" Ve r t i c a l , No O ffs e ts 330 3" - 4" 28 1" 400 0" 400 1" 550 0" 550 Ho r i zo nta l, Ve r t i c a l w i t h Offs e ts A ny E nc lo s ure F ully e nc lo s e d b y c o m b us ti b le m a te r i a l o n a ll s i d e s Une nc lo s e d , a t le a s t 1 s i d e o p e n, c o m b us ti b le m a te r i a l o n a m a xi m um o f 3 s i d e s No nc o m b us ti b le m a te r i a l • • • 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. 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. 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. 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. 29 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. C AU T I O N D o n o t o v e r tig h te n . If u s in g a v a r ia b le to r q u e d r ill, u s e a lo w to r qu e s e ttin g to in s ta ll s cr e w s , a s n o t t o s t r ip o u t t h e h o le s . If a h o le b e c o m e s s t r ip p e d d u e t o o v e r t ig h t e n in g , a la r g e r d ia m e t e r s c r e w ( ½" lo n g m a x .) o r s h o r t p o t r iv e t c a n b e u s e d . 30 8. 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 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 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. 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. 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). 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. 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. 31 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 (nonconcentric) 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. 32 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. 33 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. 34 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. 35 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. 36 H. Indoor Air Installation – See Figures 12, 13, 14, 15 and 16. 1. Do not exceed maximum vent length. Refer to Table 4. Horizontal – 2. Maintain minimum ¼ inch per foot slope in horizontal runs. 3 Recommended horizontal installation consists of vent being sloped down away from boiler. See Figure 12. 4. 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. 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. 6. For noncombustible wall application when thimble is not used, size opening such that female (bell) end with locking band attached cannot pass through. 7. Join vent terminal to vent pipe. Locate vent terminal between seventeen (17) inches and twentynine (29) inches from wall when joined to inside vent piping. See Figure 14. 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. 9. Join vent terminal to 45° elbow included in kit. 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 tee 8116304U 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. 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. 12. Whenever possible install vent straight through roof. Refer to Figure 13 if offset is necessary. Maintain minimum clearance to combustible materials. 13. Install Vent Terminal. a. Size roof opening to maintain minimum clearance from combustible materials. b. Use appropriately designed vent flashing when passing through roofs. Follow flashing manufacturers’ instructions for installation procedures. Flashing manufacturers are AirJet, American Metal Products, Metal Fab, and Simpson Dura-Vent. 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. d. Vertical venting requires flashing and a storm collar to prevent moisture from entering the structure. 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. f. Attach vent terminal. 14. Install supplied air intake terminal onto collar of the jacket enclosure. See Figure 16. 37 38 Figure 12: Recommended Separate Horizontal - Vent Installation 39 Figure 13: Alternate Separate Horizontal - Vent Installation Figure 14: Optional Indoor Air - 3” or 4” Vent Terminal Installation Figure 15: Indoor Air - Horizontal / Vertical Vent Terminal Installation Extend Vent/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 16: 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. 1. Do not exceed maximum vent/air intake lengths. Refer to Table 4. 2. This installation will allow a maximum of five (5) feet vertical exterior run of the vent/air intake piping to be installed on separate horizontal venting and indoor air horizontal venting. N OT IC E E x t e r io r r u n t o b e in c lu d e d in e q u iv a le n t v e n t /a ir in t a k e le n g t h s . 3. Install vent piping. a. Install vent piping for desired venting system. Refer to specific section for details for vent pipe 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 five (5) feet of AL 29-4C® vent pipe. Refer to Sections C through E for proper procedures for joining vent pipe and fittings. 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. e. If installation requires indoor air, install AL 29-4C® 45° elbow (provided in indoor air kit) 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. f. Install horizontal vent terminal (provided with boiler). g. Brace piping if required. 4. Air Intake Piping (not required for indoor air). a. Install air intake piping for desired venting system. Refer to specific section for details for air intake installation. b. After penetrating wall, install a corrosion resistant 90o elbow so that elbow leg is in the up direction. c. Install maximum of five (5) 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. Figure17: Optional Separate Horizontal Air 3” or 4” Intake Terminal Installation 41 Figure 18: Optional Separate Horizontal Air 5” Intake Terminal Installation Figure 19: Optional Separate Horizontal 3” Vent Terminal Installation 42 Figure 20: Optional Separate Horizontal 4” Vent Terminal Installation Figure 21: Optional Separate Horizontal 3” Vent Terminal Installation (Indoor Air) 43 Figure 22: Optional Separate Horizontal 4” Vent Terminal Installation (Indoor Air) 44 IV. Water Piping and Trim WAR N IN G F a ilu r e t o p r o p e r ly p ip e b o ile r m a y r e s u lt in im p r o p e r o p e r a t io n a n d d a m a g e t o b o ile r o r s tru c tu re . Ox y g e n c o n t a m in a t io n o f b o ile r w a t e r w ill c a u s e c o r r o s io n o f ir o n a n d s t e e l b o ile r c o m p o n e n ts , a n d c a n le a d to b o ile r fa ilu r e . B u r n h a m ' s S ta n d a r d Wa r r a n ty d o e s n o t c o v e r p r o b le m s c a u s e d b y o x y g e n c o n t a m in a t io n o f b o ile r w a t e r o r s c a le ( lim e ) b u ild - u p c a u s e d b y fr e q u e n t a d d itio n o f w a te r. 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 fittings. c. Oxygen permeable materials in the distribution system. 2. In order to insure long product life, oxygen sources must be eliminated. This can be accomplished by taking the following measures: 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. addition, some jurisdictions require the use of a LWCO with a hot water boiler. Where 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. What Kind The SCG boiler is designed to accept the wiring of the Safgard Model 1100-H4 (P/N 45-1104) LWCO. This is a probe type LWCO. The factory wiring is designed to allow simple “Plug-in” installation of the wiring. How to Pipe A “tee” is commonly used to connect the probe LWCO to the supply or return piping, as shown below. B. Low Water Cut Off (LWCO) on Hot Water Boilers (Optional) WAR N IN G D O N OT AT T E MP T to c u t fa c to ry w ire s to in s ta ll a n a fte rma rk e t L o w Wa te r C u t Off (LWC O). On ly u s e c o n n e c tio n s s p e c ific a lly id e n tifie d fo r L o w Wa te r C u t Of f . In a ll c a s e s , fo llo w th e L o w Wa te r C u t Off (LWC O) ma n u fa c tu re r' s in s tru c tio n s . 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 LWCO Location 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. 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 45 draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe. 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 45-1100) into the plug of the SCG factory wiring. 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. N OT IC E E n s u r e t h e l o c a t i o n o f t h e LW C O i n t h e p ip in g w ill a llo w fo r c o n n e c t io n o f t h e LW C O w i r i n g h a r n e s s t o t h e f a c t o r y w i r i n g o f th e S C G. 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. WAR N IN G P r e s s u r e r e lie f v a lv e d is c h a r g e p ip in g m u s t b e p ip e d s u c h t h a t t h e p o t e n t ia l o f s e v e r e b u r n s is e lim in a t e d . D O N OT p ip e in a n y a r e a w h e r e fr e e z in g c o u ld o c c u r. D O N OT in s t a ll a n y s h u t - o ff v a lv e s , p lu g s o r c a p s . C o n s u lt L o c a l C o d e s fo r p r o p e r d is c h a r g e p ip in g a r r a n g e m e n t . 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. 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. N OT IC E Burnham recommends siz ing the system circulator to supply sufficient flow (GPM) to allow a 20°F temperature differential in the system. When siz ing 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 23: Recommended Piping for Combination Heating & Cooling (Refrigeration) 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. 46 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.). Figure 24: Supply Water 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 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. 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. J. A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of installation. 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. 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. 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. 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. To perform a long term pressure test including the boiler, ALL trapped air must first be removed from the boiler. A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air. 47 48 Figure 25: Recommended Water Piping for Circulator Zoned Heating Systems 49 Figure 26: Recommended Water Piping for Zone Valve Zoned Heating Systems V. Gas Piping 4. Specific gravity of gas. Gas piping systems for gas with a specific gravity of 0.70 or less can be sized directly from Table 7, unless authority having jurisdiction specifies a gravity factor be applied. For specific gravity greater than 0.70, apply gravity factor from Table 6. If exact specific gravity is not shown choose next higher value. WAR N IN G F a ilu r e t o p r o p e r ly p ip e g a s s u p p ly t o b o ile r m a y r e s u lt in im p r o p e r o p e r a t io n a n d d a m a g e t o t h e b o i l e r o r s t r u c t u r e . Al w a y s a s s u r e g a s p ip in g is a b s o lu t e ly le a k fr e e a n d o f t h e p r o p e r s iz e a n d t y p e fo r t h e c o n n e c t e d lo a d . An a d d i t i o n a l g a s p r e s s u r e r e g u l a t o r m a y b e n e e d e d . C o n s u lt g a s s u p p lie r. Table 6: Specific Gravity Correction Factors Sp e c i f i c Gra vi ty C o r r e c ti o n F a c to r Sp e c i f i c Gra vi ty C o r r e c ti o n F a c to r supply to boiler. Consider these factors: ---- ---- 0 .8 5 0 .8 1 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. ---- ---- 0 .9 0 0 .8 2 0 .6 0 1 .0 0 1 .0 0 0 .7 8 0 .6 5 0 .9 6 1 .1 0 0 .7 4 0 .7 0 0 .9 3 1 .2 0 0 .7 1 0 .7 5 0 .9 0 1 .3 0 0 .6 8 0 .8 0 0 .8 7 1 .4 0 0 .6 6 A. Size gas piping. Design system to provide adequate gas 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). 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. 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. Table 5: Gas Ratings B o i le r Mo d e l Num b e r Na tura l/L P M a xi m um Ga s P re s s ure ( i n. w.c .) M i ni m um L P M i ni m um Na tura l Ga s P re s s ure Ga s P re s s ure ( i n. w.c .) ( i n. w.c .) Inle t to Ga s Va lve Inle t to Ga s Va lve Na tura l M a ni fo ld P re s s ure ( i n. w.c .) LP M a ni fo ld P re s s ure ( i n. w.c .) 3 .5 1 0 .5 S C G- 3 S C G- 4 S C G- 5 S C G- 6 14 4 .5 11 .5 S C G- 7 S C G- 8 S C G- 9 N OT IC E S C G b o ile r s b u ilt fo r a lt it u d e s g r e a t e r t h a n 4 ,9 9 9 fe e t a b o v e s e a le v e l n e e d t o b e s p e c ia lly o r if ic e d t o a d ju s t f o r c h a n g e s in a t m o s p h e r ic c o n d it iio n s . T h e S C G b o ile r " H " M o d e l h a s b e e n c e r t ifie d t o o p e r a t e in a t m o s p h e r ic c o n d it io n s fr o m 5 ,0 0 0 t o 1 0 ,0 0 0 fe e t a b o v e s e a le v e l. In p u t is d e r a t e d b y 1 0 % fo r a p p lic a t io n s a t 5 ,0 0 0 fe e t a b o v e s e a le v e l, a n d 2 0 % fo r a p p lic a t io n s a t 1 0 ,0 0 0 fe e t a b o v e s e a le v e ls . D e r a t e is b a s e d o n 2 % r e d u c t io n p e r 1 0 0 0 fe e t . T h e S C G b o ile r is a v a ila b le in t w o ( 2 ) a lt it u d e M o d e ls : T h e " S " M o d e l 0 - 4 ,9 9 9 fe e t a b o v e s e a le v e l, a n d t h e " H " M o d e l 5 ,0 0 0 - 1 0 ,0 0 0 fe e t a b o v e s e a le v e l. F o r a p p lic a tio n s a b o v e 1 0 ,0 0 0 fe e t, c o n s u lt th e m a n u fa c tu r e r. 50 Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Gas Pressures of 0.5 psig or Less 0 .3 i nc h w.c . P re s s ure D ro p 0 .5 i nc h w.c . P re s s ure D ro p L e ng th [F e e t] ½ ¾ 1 1¼ ½ ¾ 1 1¼ 10 132 278 520 1 ,0 5 0 175 360 680 1 ,4 0 0 20 92 190 350 730 120 250 465 950 30 73 152 285 590 97 200 375 770 40 63 130 245 500 82 170 320 660 50 56 11 5 215 440 73 151 285 580 60 50 105 195 400 66 138 260 530 70 46 96 180 370 61 125 240 490 80 43 90 170 350 57 11 8 220 460 90 40 84 160 320 53 11 0 205 430 100 38 79 150 305 50 103 195 400 * 1 CFH of Natural Gas is approximately equal to 1 MBH; 1 CFH of LP is approximately equal to 2.5 MBH; contact your gas supplier for the actual heating value of your gas. B. Connect boiler gas valve to gas supply system. WAR N IN G F a ilu r e t o u s e p r o p e r t h r e a d c o m p o u n d s o n a ll g a s c o n n e c t o r s m a y r e s u lt in le a k s o f fla m m a b le g a s . WAR N IN G Ga s s u p p ly t o b o ile r a n d s y s t e m m u s t b e a b s o lu t e ly s h u t o ff p r io r t o in s t a llin g o r s e r v ic in g b o ile r g a s p ip in g . 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 27: Recommended Gas Piping Table 8: Equivalent Lengths of Standard Pipe Fittings & Valves VA LV E S F UL LY OP E N Pi pe S i ze I. D . Inc he s Ga te G lo b e A ng le S wi ng C he c k 90° E lb o w 45° E lb o w 9 0 ° Te e , F lo w Thro ug h Run 9 0 ° Te e , F lo w Thro ug h B ra nc h ½" 0 .6 2 2 0 .3 5 1 8 .6 9 .3 4 .3 1 .6 0 .7 8 1 .0 3 .1 ¾" 0 .8 2 4 0 .4 4 2 3 .1 11 .5 5 .3 2 .1 0 .9 7 1 .4 4 .1 1" 1 .0 4 9 0 .5 6 2 9 .4 1 4 .7 6 .8 2 .6 1 .2 3 1 .8 5 .3 1 ¼" 1 .3 8 0 0 .7 4 3 8 .6 1 9 .3 8 .9 3 .5 1 .6 0 2 .3 6 .9 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. C. Pressure test. The boiler and its gas connection must 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 52 piping by closing boiler’s individual manual shutoff valve. 2. Locate leaks using approved combustible gas detector, soap and water, or similar nonflammable solution. D AN G E R D o n o t u s e m a t c h e s , c a n d le s , o p e n fla m e s o r o t h e r ig n it io n s o u r c e t o c h e c k fo r le a k s . VI. Electrical DANGER P o s it iv e ly a s s u r e a ll e le c t r ic a l c o n n e c t io n s a r e u n p o w e r e d b e f o r e a t t e m p t in g in s t a lla t io n o r s e r v ic e o f e le c t r ic a l c o m p o n e n t s o r c o n n e c t io n s o f t h e b o ile r o r b u ild in g . L o c k o u t a ll e le c t r i c a l b o x e s w it h p a d lo c k o n c e p o w e r is t u r n e d o f f . WAR N IN G F a ilu r e t o p r o p e r ly w ir e e le c t r ic a l c o n n e c t io n s t o t h e b o ile r m a y r e s u lt in s e r io u s p h y s ic a l h a rm. E le c t r ic a l p o w e r m a y b e fr o m m o r e t h a n o n e s o u r c e . M a k e s u r e a ll p o w e r is o ff b e fo r e a t t e m p t in g a n y e le c t r ic a l w o r k . E a c h b o ile r m u s t b e p r o t e c t e d w it h a p r o p e r ly s iz e d o v e r - c u r r e n t d e v ic e . N e v e r ju m p o u t o r m a k e in o p e r a t iv e a n y s a f e t y o r o p e r a t in g c o n t r o ls . T h e w ir in g d ia g r a m s c o n ta in e d in th is m a n u a l a r e fo r r e fe r e n c e p u r p o s e s o n ly. E a c h b o ile r is s h ip p e d w ith a w ir in g d ia g r a m a tta c h e d to th e fr o n t d o o r. R e fe r to th is d ia g r a m a n d th e w ir in g d ia g r a m o f a n y c o n tr o ls u s e d w ith th e b o ile r. R e a d , u n d e r s ta n d a n d fo llo w a ll w ir in g in s t r u c t io n s s u p p lie d w it h t h e c o n t r o ls . A. General. Install wiring and electrically ground boiler B. 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. 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 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. C. Refer to Figures 28 and 29 for details on the internal boiler wiring. N OT IC E T h is b o ile r is e q u ip p e d w it h a h ig h w a t e r t e m p e r a t u r e lim it lo c a t e d in s id e t h e in t e r n a l w ir in g o f th e b o ile r. T h is lim it p r o v id e s b o ile r s h u td o w n in th e e v e n t th e b o ile r w a te r te m p e r a tu r e e x c e e d s t h e s e t p o in t o f t h e lim it c o n t r o l. C e r t a in L o c a l C o d e s r e q u ir e a n a d d it io n a l w a t e r t e m p e r a t u r e lim it . In a d d it io n , c e r t a in t y p e s o f s y s t e m s m a y o p e r a t e a t t e m p e r a t u r e s b e lo w t h e m in im u m s e t p o in t o f th e lim it c o n ta in e d in th e b o ile r. I f t h i s o c c u r s , i n s t a l l a n a d d i t i o n a l w a t e r t e m p e r a t u r e l i m i t ( H o n e y w e l l L 4 0 0 6 Aq u a s t a t ) l o c a t e d i n th e s y s te m p ip in g a s s h o w n in th e Wa te r P ip in g a n d Tr im S e c tio n o f th is m a n u a l. W ir e a s in d ic a t e d in t h e E le c t r ic a l S e c t io n o f t h is m a n u a l. N OT IC E Al l w i r e , w i r e n u t s , c o n t r o l s e t c . a r e i n s t a l l e r s u p p l i e d u n l e s s o t h e r w i s e n o t e d . 53 54 Figure 28: Internal Boiler Wiring Schematic Diagram N OT IC E If a n a d d it io n a l s y s t e m lim it is u s e d , in s t a ll in s e r ie s w it h t h e a u x ilia r y lim it ju m p e r s h o w n in t h e d r a w in g b e lo w. Figure 29: 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. N OT IC E T h e H o n e y w e l l R 8 8 8 8 C o n t r o l i s a v a i l a b l e i n a t h r e e ( 3 ) z o n e M o d e l ( R 8 8 8 8 A) a n d a f o u r ( 4 ) z o n e M o d e l ( R 8 8 8 8 B ) . U p t o fo u r ( 4 ) R 8 8 8 8 ' s m a y b e u s e d t o g e t h e r t o p r o v id e c o n t r o l fo r u p t o t w e lv e ( 1 2 ) in d iv id u a l z o n e s . On ly o n e ( 1 ) z o n e , t h e fir s t z o n e o f t h e m a in c o n t r o l, w ill p r o v id e p r io r it y c i r c u l a t i o n . I f m o r e t h a n f o u r ( 4 ) z o n e s a r e r e q u i r e d , c o n n e c t a d d i t i o n a l R 8 8 8 8 ' s b y w i r i n g t h e A, B , a n d C te r m in a ls o f e a c h c o n tr o l to g e th e r. E a c h R 8 8 8 8 r e q u ir e s a 1 2 0 v o lt p o w e r s u p p ly. If m o r e t h a n o n e ( 1 ) R 8 8 8 8 is u s e d , s e t t h e p a n e l t y p e s w it c h t o " m a in " o n t h e fir s t R 8 8 8 8 a n d s e t t h e p a n e l t y p e s w it c h t o " e x p a n s io n " o n t h e s e c o n d , t h ir d o r fo u r t h R 8 8 8 8 . 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. N OT IC E T h e H o n e y w e ll R 8 8 8 9 C o n t r o l is a v a ila b le in t w o t h r e e ( 3 ) z o n e m o d e ls a n d t w o fo u r ( 4 ) z o n e m o d e ls . B u r n h a m r e c o m m e n d s u s in g M o d e l R 8 8 8 9 A fo r t h r e e ( 3 ) z o n e s y s t e m s a n d M o d e l R 8 8 8 9 B fo r fo u r ( 4 ) z o n e s y s t e m s . M o d e ls R 8 8 8 9 C a n d R 8 8 8 9 D h a v e le s s lo a d c a p a c it y a n d m a y n o t o p e r a t e w it h c e r t a in t y p e s o f z o n e v a lv e s . U p t o fo u r ( 4 ) R 8 8 8 9 ' s m a y b e u s e d t o g e t h e r t o p r o v id e u p t o s ix t e e n ( 1 6 ) in d iv id u a l z o n e s . On ly o n e ( 1 ) z o n e , t h e fir s t z o n e o f t h e m a in c o n t r o l w ill p r o v id e p r io r ity z o n in g fo r th e Allia n c e in d ir e c t w a te r h e a te r. If m o r e th a n fo u r (4 ) z o n e s a r e r e q u ir e d , c o n n e c t a d d itio n a l R 8 8 8 9 ' s b y w ir in g th e A, B a n d C te r m in a ls o f e a c h c o n tr o l to g e th e r. E a c h R 8 8 8 9 r e q u ir e s a 1 2 0 v o lt p o w e r s u p p ly. If m o r e th a n o n e (1 ) R 8 8 8 9 is u s e d , s e t th e p a n e l t y p e s w it c h t o " m a in " o n t h e fir s t R 8 8 8 9 a n d s e t t h e p a n e l t y p e s w it c h t o " e x p a n s io n " o n t h e s e c o n d , t h ir d o r fo u r t h R 8 8 8 9 . 56 57 Figure 30: System Wiring Schematic for Single Zone Space Heating Only N OT IC E Figure 31: Single Zone System with Packaged Alliance™ Water Heater Wiring Schematic If a n a d d it io n a l s y s t e m lim it is u s e d , in s t a ll in s e r ie s w it h t h e a u x ilia r y lim it ju m p e r s h o w n in t h e d r a w in g b e lo w. 58 59 Figure 32: Circulator Zoned System Wiring Schematic 60 Figure 33: Zone Valve Zoned System Wiring Schematic Figure 34: Different Manufacturer’s Zone Valve Connections to Honeywell R8889 61 VII. Modular Installation 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, NFPA 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. B. Module Sizing Burnham recommends sizing each boiler in a modular system to provide 20 % of the combined heating load where ever possible. C. Venting 1. Each boiler must have an individual vent pipe. Refer to Venting Section of this manual for venting guidelines and options. WAR N IN G D o n o t m a n ifo ld v e n t p ip e s to g e th e r. 2. The maximum vent length for each boiler is fifty (50) equivalent feet. 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. C AU T I O N In s t a llin g m u lt ip le v e n t t e r m in a t io n s c lo s e t o g e t h e r p r o m o t e s fr o s t b u ild u p o n b u ild in g s . To m in im iz e th is p o s s ib ility, e x t e n d t h e d is t a n c e fr o m t h e b u ild in g t o t h e e n d o f t h e v e n t t e r m in a t io n a n d in c r e a s e t h e h o r iz o n t a l d is t a n c e b e t w e e n t e r m in a t io n s . 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. 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. 2. The maximum air intake length for each boiler is fifty (50) equivalent feet. 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 62 with vertical venting and sidewall combustion air inlet (or visa versa) if installation conditions do not allow alternate arrangement. Table 9: Modular Boiler Water Manifold Sizing C o m b i ne d Outp ut ( M B H) Re c o m m e nd e d M i ni m um C o m m o n Wa te r M a ni fo ld S i ze ( NP T) < 166 1 ¼" < 260 1 ½" < 550 2" < 900 2 ½" < 2000 3" 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. F. Gas Piping 1. Refer to National Fuel Gas Code, Local Codes and Tables 7 and 8 for gas pipe sizing. 2. Each boiler must be piped as shown in Figure 27. WAR N IN G If g a s p r e s s u r e in t h e b u ild in g is a b o v e ½ p s ig , a n a d d it io n a l g a s p r e s s u r e r e g u la t o r is r e q u ir e d . U s in g o n e a d d it io n a l r e g u la t o r fo r m u lt ip le b o ile r s m a y r e s u lt in u n s a fe b o ile r o p e r a t io n . T h e a d d it io n a l r e g u la t o r m u s t b e a b le t o p r o p e r ly r e g u la t e g a s p r e s s u r e a t th e in p u t o f th e s m a lle s t b o ile r. If t h e r e g u la t o r c a n n o t d o t h is , t w o o r m o r e a d d it io n a l r e g u la t o r s a r e r e q u ir e d . C o n s u lt r e g u la t o r m a n u f a c t u r e r a n d /o r lo c a l g a s s u p p lie r fo r in s t r u c t io n s a n d e q u ip m e n t r a t in g s . G. Electrical 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. H. Modular Boiler Control Systems Contact a controls manufacturer such as Honeywell or Tekmar to properly apply a modular control system. Common systems may use outdoor temperature, return water temperature or both to stage the boilers. 63 Figure 35: Modular Boiler Gas Piping VIII. System Start-up 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 LowPressure Steam and Hot Water Boilers, ANSI Z21.13. B. Verify that the venting, water piping, gas piping and electrical system are installed properly. Refer to installation instructions contained in this manual. C. Confirm all electrical, water and gas supplies are turned off at the source and that vent is clear of obstructions. D. Confirm that all manual shut-off gas valves between the boiler and gas source are closed. WAR N IN G C o m p le t e ly r e a d , u n d e r s t a n d a n d fo llo w a ll in s t r u c t io n s in t h is m a n u a l b e fo r e a t t e m p t in g s t a r t u p . 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. WAR N IN G T h e m a x im u m o p e r a t in g p r e s s u r e o f t h is b o ile r is 3 0 p s ig . N e v e r e x c e e d t h is p r e s s u r e . D o n o t p lu g o r c h a n g e p r e s s u r e r e lie f v a lv e . N OT IC E If it is r e q u ir e d t o p e r f o r m a lo n g t e r m p r e s s u r e te s t o f th e h y d r o n ic s y s te m , th e b o ile r s h o u ld fir s t b e is o la te d to a v o id a p r e s s u r e lo s s d u e to th e e s c a p e o f a ir tr a p p e d in th e b o ile r. To p e r f o r m a l o n g t e r m p r e s s u r e t e s t in c lu d in g th e b o ile r, AL L tr a p p e d a ir m u s t fir s t b e r e m o v e d fr o m th e b o ile r. A lo s s o f p r e s s u r e d u r in g s u c h a te s t, w ith n o v is ib le w a te r le a k a g e , is a n in d ic a tio n th a t th e b o ile r c o n ta in e d tr a p p e d a ir. 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). 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). 64 4. Starting with one circuit at a time, open zone valve or shut-off valve in system supply and return piping. 5. Open hose bib. 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). 7. Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds. 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. 9. Close hose bib, continue filling the system until the pressure gauge reads 12 psi. Close fill valve. (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). 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. G. Prepare to check operation. 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. 3. Temporarily turn off all other gas-fired appliances. 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. 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. D AN G E R D o n o t u s e m a t c h e s , c a n d le s , o p e n fla m e s o r o t h e r ig n it io n s o u r c e t o c h e c k fo r le a k s . 8. Purge gas line of air. Figure 36: Operating Instructions 65 Figure 38: 1 Inch Main Burner flame Figure 39: Pilot Burner Flame K. Check main burner flame. See Figures 38. Flame should have clearly defined inner cone with no yellow 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 Figure 37: Sequence of Operation pilot lead wires from gas valve. If burners do not shutdown, determine cause of malfunction. Replace necessary items and check operation. N. Check low water cutoff (if so equipped). 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 Troubleshooting Tree in Section IX: Service. J. Check pilot burner flame. See Figure 39. Flame should be steady, medium hard blue enveloping 3/8 to ½ inch of sensing probe. 66 1. Adjust thermostat to highest setting. 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. 4. Adjust thermostat to lowest setting. Refill boiler. 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. Ignition sequence should begin. 4. Adjust thermostat to lowest setting. Adjust limit to desired setting. P. Adjust gas input rate to boiler. 1. Adjust thermostat to highest setting. 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. 3. Clock gas meter for at least 30 seconds. Use Table 10 to determine gas flow rate in Cubic Feet per Hour. WAR N IN G F a ilu r e t o p r o p e r ly a d ju s t g a s in p u t r a t e w ill r e s u lt in o v e r fir in g o r u n d e r fir in g o f t h e a p p lia n c e . Im p r o p e r a n d u n s a fe b o ile r o p e r a t io n m a y r e s u lt . 4. Determine Input Rate. Multiply gas flow rate by gas heating value. 5. Compare measured input rate to input rate stated on rating plate. 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. b. Increase input rate if less than 98% of rating plate input. Increase manifold gas pressure no more than 0.3 inch w.c. If measured input rate is still less than 98% of rated input: 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). iii. Reinstall gas orifices and main burners. Measure input rate. 6. Recheck Main Burner Flame. 7. Return other gas-fired appliances to previous conditions of use. Q. Review User’s Information Manual and system operation with owner or operator. Table 10: Gas Flow Rate in Cubic Feet Per Hour S e c o nd s fo r One Re vo luti o n S i ze o f Ga s M e te r D i a l One -Ha lf C u. F t. One C u. F t. Two C u. F t. 30 60 120 240 32 56 11 3 225 34 53 106 212 36 50 100 200 38 47 95 189 40 45 90 180 42 43 86 172 44 41 82 164 46 39 78 157 48 37 75 150 50 36 72 144 52 35 69 138 54 33 67 133 56 32 64 129 58 31 62 124 60 30 60 120 67 IX. Service D AN G E R T h is b o ile r u s e s fla m m a b le g a s , h ig h v o lta g e e le c tr ic ity, m o v in g p a r ts , a n d v e r y h o t w a te r u n d e r h i g h p r e s s u r e . As s u r e t h a t a l l g a s a n d e l e c t r i c p o w e r s u p p l i e s a r e o f f a n d t h a t t h e w a t e r t e m p e r a t u r e is c o o l b e fo r e a t t e m p t in g a n y d is a s s e m b ly o r s e r v ic e . As s u r e t h a t a l l g a s v a l v e s a n d e l e c t r i c a l d i s c o n n e c t s w i t c h e s a r e o f f b e f o r e a t t e m p t i n g a n y d is a s s e m b ly o r s e r v ic e . D o n o t a tte m p t a n y s e r v ic e w o r k if g a s is p r e s e n t in th e a ir in th e v ic in ity o f th e b o ile r. N e v e r m o d ify, r e m o v e o r ta m p e r w ith a n y c o n tr o l d e v ic e . WAR N IN G T h is b o ile r m u s t o n ly b e s e r v ic e d a n d r e p a ir e d b y s k ille d a n d e x p e r ie n c e d s e r v ic e t e c h n ic ia n s . If a n y c o n t r o ls a r e r e p la c e d , t h e y m u s t b e r e p la c e d w it h id e n t ic a l m o d e ls . R e a d , u n d e r s t a n d a n d fo llo w a ll t h e in s t r u c t io n s a n d w a r n in g s c o n t a in e d in a ll t h e s e c t io n s o f t h is m a n u a l. If a n y e le c t r ic a l w ir e s a r e d is c o n n e c t e d d u r in g s e r v ic e , c le a r ly la b e l t h e w ir e s a n d a s s u r e th a t th e w ir e s a r e r e c o n n e c te d p r o p e r ly. N e v e r ju m p o u t o r b y p a s s a n y s a fe ty o r o p e r a tin g c o n tr o l o r c o m p o n e n t o f th is b o ile r. R e a d , u n d e r s t a n d a n d f o l l o w a l l t h e i n s t r u c t i o n s a n d w a r n i n g s c o n t a i n e d i n AL L o f t h e c o m p o n e n t in s t r u c t io n m a n u a ls . As s u r e t h a t a l l s a f e t y a n d o p e r a t i n g c o n t r o l s a n d c o m p o n e n t s a r e o p e r a t i n g p r o p e r l y b e f o r e p la c in g t h e b o ile r b a c k in s e r v ic e . 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 37. 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. C. Vent/Air Intake System. Inspect for obstructions, soot accumulation, proper support, and deterioration of pipe, fittings, and joints. 1. Clean terminal screens. Terminals must be free of obstruction, undamaged, with screens securely in place. 2. Terminal and wall thimbles (if used) must be weathertight. 3. Pipe must be full round shape, and show no damage from impact or excessive temperature. 68 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: 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. D. Boiler Flue Passages. Inspect for blockage or soot accumulation. 1. Remove Main Burners. See Figure 42. a. Remove front door. b. Remove air intake box front door. i. Remove sheet metal screws. c. Disconnect pilot tubing and pilot lead wires at the gas valve. d. e. f. g. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove wires to Flame Roll-out Switch. Remove air diffuser screen. Remove Burner Access Panel. 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. Disconnect Vent Connector and Vent Pipe from Blower Outlet Remove Jacket Top Panel. Disconnect the Black and Gary Silicone Tubing from the Canopy. Disconnect Wiring Harness from Blower Motor. Remove Canopy/Blower Assembly. a. Loosen the (4) screws from Canopy. Remove Flue Gas Baffles. Inspect Flue Gas Baffles for deterioration. Inspect flue passages. Clean with flue brush. See Figure 42. Inspect heating surface in combustion chamber. Clean with straight handle wire brush. Install Flue Gas Baffles. Replace Canopy/Blower Assembly. Connect Silicone Tubing between Pressure Fittings on Canopy Assembly and Pressure Switch. Route through bushings in Vestibule Panel . See Figure 40. Figure 41: Blower Vent Connector Assembly 13. Install Jacket Top Rear Panel. 14. Connect Vent System. See Figure 41. 15. Connect Blower Motor Wiring Harness. E. Main Burners and Firebox. 1. Vacuum firebox. Exercise care - do not damage base insulation. 2. Clean main burners. Brush top of burners with soft bristle brush. See Figure 42. Vacuum to remove any dirt and lint. 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 11. b. Main burners must be properly secured in burner tray slot at rear of firebox and over gas orifice. See Figure 42. 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. Figure 40: Silicone Tubing Assembly 69 70 Figure 42: Flue and Burner Cleanout, 1” Burner Table 11: Pilot Burner Location B o i le r M o d e l M a i n B urne r wi th P i lo t B ra c k e t P i lo t B urne r L o c a te d B e twe e n M a i n B urne rs * S C G- 3 2 2 & 3 S C G- 4 3 3 & 4 S C G- 5 4 4 & 5 S C G- 6 5 5 & 6 S C G- 7 6 6 & 7 S C G- 8 7 7 & 8 S C G- 9 8 8 & 9 * M a i n b ur ne r s num b e r e d le ft to r i g ht a s vi e we d fr o m fr o nt o f b o i le r. G. Procedure for Measuring Differential Pressure (See Figure 43). 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 12 for minimum readings. NOTE: If switch drops-out before boiler reaches temperature or if pressure differential readings are below minimums shown in Table 12, check for cracks in hose or contact your nearest Burnham representative. 4. Stop boiler, remove manometer and reconnect hoses to differential pressure switch. See Figures 40 and 43. Figure 43: Differential Pressure Measurement Table 12: Differential Pressure Switch Settings M i ni m um D i ffe re nti a l P re s s ure B o i le r M o d e l S e a L e ve l to 4 ,9 9 9 F t. 5 ,0 0 0 - 1 0 ,0 0 0 F t. E le va ti o n S C G- 3 1 .3 2 " w.c . .8 0 " w.c . S C G- 4 1 .1 7 " w.c . .6 5 " w.c . S C G- 5 1 .1 7 " w.c . .6 5 " w.c . S C G- 6 .8 8 " w.c . .3 5 " w.c . S C G- 7 .8 0 " w.c . .3 0 " w.c . S C G- 8 .8 8 " w.c . .3 5 " w.c . S C G- 9 .8 8 " w.c . .3 5 " w.c . 71 72 73 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. 74 Key No . [Qua nti ty] P a rt Num b e r D e s c r i p ti o n S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 61707041 61707051 51707061 61707071 61707081 61707091 (5 ) 71707003 (6 ) 71707003 (7 ) 71707003 1 . C A S T I N G A S S E M B LY 1 S e c ti o n A s s e m b ly 61707031 1A L e ft E nd S e c ti o n 1B C e nte r S e c ti o n 1C Ri g ht E nd S e c ti o n 1D S li p Ni p p le , # 3 1E F lue Ga s B a ffle (2 ) 7 11 0 7 0 0 2 (3 ) 7 11 0 7 0 0 2 (4 ) 7 11 0 7 0 0 2 (5 ) 7 11 0 7 0 0 2 (6 ) 7 11 0 7 0 0 2 (7 ) 7 11 0 7 0 0 2 (8 ) 7 11 0 7 0 0 2 1F Ti e Ro d , ¼" - 2 0 (2 ) 1 0 0 1 0 9 -0 1 (2 ) 1 0 0 1 0 8 -0 5 (2 ) 1 0 0 1 0 8 -0 7 (2 ) 1 0 0 1 0 8 -1 3 (2 ) 1 0 0 1 0 8 -1 4 (2 ) 1 0 0 1 0 8 -1 5 (2 ) 1 0 0 1 0 8 -1 6 1G He x Nut, ¼" - 2 0 71707001 (1 ) 71707003 (2 ) 71707003 (3 ) 71707003 (4 ) 71707003 71707002 (4 ) (6 ) (8 ) (1 0 ) (1 2 ) (1 4 ) (1 6 ) 806600009 806600009 806600009 806600009 806600009 806600009 806600009 (4 ) 8 0 8 6 0 4 0 7 75 76 Key D e s c r i p ti o n No . [Qua nti ty] P a rt Num b e r S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 2 . B A S E A S S E M B LY 2A B a s e W ra p p e r 71807031 71807041 71807051 71807061 71807071 71807081 71807091 2B B a s e Tr a y 71807032 71807042 71807052 71807062 71807072 71807082 71807092 2C B ur ne r Tr a y A s s e m b ly 61807031 61807041 61807051 61807061 61807071 61807081 61807091 2D B a s e F r o nt P a ne l 71807035 71807045 71807055 71807065 71807075 71807085 71807095 2E B ur ne r A c c e s s P a ne l 71807036 71807046 71807056 71807066 71807076 71807086 71807096 2F C e r a fe lt G a s k e t 1 /2 " x 2 " 6206002 2G C e r a fe lt G a s k e t 1 /2 " x 2 " 6206002 2H B a s e S i d e Ins ula ti o n 2J B a s e Re a r Ins ula ti o n 72007031 72007041 72007051 72007061 72007071 72007081 72007091 2K B a s e F r o nt Ins ula ti o n 72007032 72007042 72007052 72007062 72007072 72007082 72007092 2L B a s e L e g A s s e m b ly (2 ) 7 2 0 0 7 0 0 1 (4 ) 6 1 8 6 0 0 1 2 M S e lf Ta p p i ng S c r e w, 1 /4 " - 2 0 x 1 /2 " (1 8 ) 8 0 8 6 0 7 0 0 2N F la m e Ro ll- o ut S wi tc h 80160044 2P S he e t M e ta l S c r e w, # 8 x 3 /4 " 80860030 2Q S e lf Ta p p i ng S c r e w, 1 0 - 3 2 x 3 /8 " 2R S e ft Ta p p i ng S c r e w He x C a p , 5 /1 6 - 1 8 x 3 /4 " (5 ) 8 0 8 6 0 7 0 5 (6 ) 8 0 8 6 0 7 0 (7 ) 8 0 8 6 0 7 0 (4 ) 8 0 8 6 0 7 1 7 77 78 Key D e s c r i p ti o n No . [Qua nti ty] P a rt Num b e r S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 3 . B A S E E N C L O S U R E A S S E M B LY 3A A i r B o x A s s e m b ly 61807032 61807042 61807052 61807062 61807072 61807082 61807092 3B Ai r Box D oor 71807034 71807044 71807054 71807064 71807074 71807084 71807094 3C C o m b us ti o n A i r D i ffus e r 3D P i lo t Tub e Ga s k e t C o ve r P la te 7096002 3E P i lo t Tub e Ga s k e t 8206038 3F Ob s e r va ti o n P o r t Ga s k e t 3G Ob s e r va ti o n P o r t L e ns 8026082 3H Ob s e r va ti o n P o r t L e ns Re ta i ne r 7186019 3J S he e t M e ta l S c r e ws # 8 x 1 /2 " 3K S e lf Ta p p i ng S c r e w, 1 0 - 3 2 x 3 /8 " N/A 71807049 71807059 71807069 71807079 71807089 71807099 (2 ) 8 2 0 6 0 3 9 (1 0 ) 8 0 8 6 0 0 0 0 (1 8 ) 8 0 8 6 0 7 0 5 (2 2 ) 8 0 8 6 0 7 0 5 79 80 Key D e s c r i p ti o n No . [Qua nti ty] P a rt Num b e r S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 4 . FA N / C A N O P Y A S S E M B LY C a no p y A s s e m b ly - S e a L e ve l 6 11 0 7 0 3 1 6 11 0 7 0 4 1 6 11 0 7 0 5 1 6 11 0 7 0 6 1 6 11 0 7 0 7 1 6 11 0 7 0 8 1 6 11 0 7 0 9 1 C a no p y A s s e m b ly - Hi g h A lti tud e 6 11 0 7 0 3 2 4A 61107042 61107052 6 11 0 7 0 6 2 4B C e r a fe lt 4C U- C li p (4 ) 8 0 8 6 1 5 1 2 4D S he e t M e ta l S c r e w, # 1 0 x 3 /4 " (4 ) 8 0 8 6 0 0 1 3 4E F a n Ga s k e t 8206085 4F Fan 8 11 6 1 5 1 2 4G L o c k Wa s he r, # 1 0 4H M a c hi ne S c r e w, # 1 0 - 2 4 x 2 - 1 /2 " 6 11 0 7 0 7 2 6 11 0 7 0 8 2 6 11 0 7 0 9 2 9206005 (4 ) 8 0 8 6 0 6 3 6 (4 ) 8 0 8 6 0 8 9 8 2 81 82 Key No . [Qua nti ty] P a rt Num b e r D e s c r i p ti o n S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 5 . B U R N E R AS S E M B L I E S Ga s Va lve ( Na tur a l Ga s ) , Ho ne ywe ll V R8 2 0 4 P 11 7 1 81660282 N/A Ga s Va lve ( Na tur a l Ga s ) , Ho ne ywe ll V R8 3 0 4 P 4 4 9 6 N/A 81660283 Ga s Va lve ( L P Ga s ) , Ho ne ywe ll V R8 2 0 4 C 3 0 1 5 81660146 N/A Ga s Va lve ( L P Ga s ) , Ho ne ywe ll V R8 3 0 4 P 4 2 8 0 N/A 81660181 Ni p p le , ½ " NP T x C lo s e 806600040 N/A Ni p p le , ¾ " NP T x C lo s e N/A 806600022 Uni o n, ½" NP T 506604023 N/A Uni o n, ¾" NP T N/A 806604001 5A 5B 5C Ga s M a ni fo ld 82207031 82207041 82207051 82207061 82207071 82207081 82207091 B ur ne r Or i fi c e s - Na tur a l Ga s # 4 7 (4 ) 822710 (6 ) 822710 (8 ) 822710 (1 0 ) 822710 (1 2 ) 822710 (1 4 ) 822710 (1 6 ) 822710 B ur ne r Or i fi c e s - L P Ga s 1 .2 0 m m (4 ) 822792 (6 ) 822792 (8 ) 822792 (1 0 ) 822792 (1 2 ) 822792 (1 4 ) 822792 (1 6 ) 822792 5D ¾" Ga s M a ni fo ld 5E P i lo t A s s e m b ly - Na tur a l Ga s 8236163 P i lo t A s s e m b ly - L P G a s 8236164 5F 5G P i lo t B ur ne r 1 0 0 1 4 7 -0 1 5H M a i n B ur ne r (3 ) (5 ) (7 ) (9 ) (11 ) (1 3 ) (1 5 ) 1 0 0 1 4 6 -0 1 1 0 0 1 4 6 -0 1 1 0 0 1 4 6 -0 1 1 0 0 1 4 6 -0 1 1 0 0 1 4 6 -0 1 1 0 0 1 4 6 -0 1 1 0 0 1 4 6 -0 1 5J P i lo t Tub i ng 8236122 5K S e lf Ta p p i ng S c r e w, 1 /4 - 2 0 x1 /2 " (6 ) 8 0 8 6 0 7 0 0 83 84 Key No . [Qua nti ty] P a rt Num b e r D e s c r i p ti o n S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 6 . C O N T R O L P A N E L A S S E M B LY 6A L i m i t, Ho ne ywe ll L 4 0 8 0 D 6B Tr a ns fo r m e r /Re la y, Ho ne ywe ll R8 2 8 5 D 6C Ig ni ti o n M o d ule , Ho ne ywe ll S8670E1007 6D B lo we r Re la y, Ho ne ywe ll R8 2 2 2 U1 0 0 6 80160762 80160761 80160760 80160759 80160760 6E D i ffe r e nti a l P r e s s ur e S wi tc h S e a L e ve l 0 ' - 4 9 9 9 ' Hi g h A lti tud e - 5 0 0 0 ' - 1 0 ,0 0 0 ' 80160759 80160763 80160764 80160765 80160764 6F J unc ti o n B o x 80160156 80160155U 80160108 80160096U 8136259 85 86 Key No . [Qua nti ty] P a rt Num b e r D e s c r i p ti o n S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 7 . J A C K E T PA R T S 7A J a c k e t L e ft S i d e P a ne l 60407002 7B J a c k e t Ri g ht S i d e P a ne l 60407001 7C Re a r P a ne l 60407033 60407043 60407053 60407063 60407073 60407083 60407093 7D Ve s ti b ule P a ne l 60407034 60407044 60407054 60407064 60407074 60407084 60407094 7E To p P a ne l 60407032 60407042 6040752 60407062 60407072 60407082 60407092 7F F r o nt D o o r 70407031 70407041 70407051 70407061 70407071 70407081 70407091 7G A i r Inta k e C o lla r A s s e m b ly 7H Ha nd le 7J D o o r C li p 7K B us hi ng 7L B ur nha m L o g o 60407003 60407004 60407005 8056184 (2 ) 7 0 4 1 9 2 1 8136048 81460099 87 Key No . [Qua nti ty] P a rt Num b e r D e s c r i p ti o n S C G- 3 S C G- 4 S C G- 5 S C G- 6 S C G- 7 S C G- 8 S C G- 9 8. M IS C E L L AN E OU S P AR T S C AR T ON 88 8A Wa te r M a ni fo ld 80607001 8B Te m p e r a tur e /P r e s s ur e Ga ug e 8056169 8C C i r c ula to r W i r i ng Ha r ne s s 6130701 8D S a fe ty Re li e f Va lve 81660363 8E B o i le r D r a i n Va lve 806603061 8F Ve nt Te r m i na l 8G A i r Inta k e Te r m i na l 8H Ve nt C o nne c to r 8 11 0 7 0 1 6 11 6 0 4 5 6 11 6 0 4 4 8 11 0 7 0 3 8 11 0 7 0 2 6 11 6 0 6 3 8 11 0 7 0 4 Im p o r t a n t P r o d u c t S a fe t y In fo r m a t io n R e fr a c t o r y C e r a m ic F ib e r P r o d u c t Warning: This product contains refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. After this product is fired, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health. AVOID Breathing Fiber Particulates and Dust Precautionary Measures: Do not remove or replace previously fired RCF (combustion chamber insulation, target walls, canopy gasket, flue cover gasket, etc.) 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 air tight plastic bag. 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. 89 SERVICE RECORD DATE 90 SERVICE PERFORMED SERVICE RECORD DATE SERVICE PERFORMED 91 Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS 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: 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. 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: Years In Service Service Charge as % of Retail Price Years In Service Service Charge as % of Retail Price 1-10 11 12 13 14 15 16 17 No Charge 5 10 15 20 25 30 35 18 19 20 21 22 23 24 25 and above 40 45 50 55 60 65 70 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. 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. 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. 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. 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 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. 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. 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. 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 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. 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. 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. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. 4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Co., Inc. conditioned upon the use of the residential grade 03/03
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