Burnham SCG 1100-H4 Installation & Service Instructions Manual
Burnham SCG 1100-H4 Installation & Service Instructions Manual

Burnham SCG 1100-H4 Installation & Service Instructions Manual

Scg series gas - fired boiler

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Price - $5.00

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Summary of Contents for Burnham SCG 1100-H4

  • Page 1 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). ® 8140705R9-10/08 ™ Price - $5.00...
  • Page 2 The City of New York requires a Licensed Master Plumber 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.
  • Page 3 All cover plates, enclosures and guards must be in place at all times. This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete.
  • Page 4: Table Of Contents

    Table of Contents I. Pre-Installation ..6 II. Unpack Boiler ... 7 III. Venting/Air Intake Piping ... 8 IV. Water Piping and Trim ... 45 V. Gas Piping ..50 Figure 1: Minimum Clearances to Combustibles VI. Electrical ..53 VII. Modular Installation ... 62 VIII. System Start-up ... 64 IX. Service ... 71...
  • Page 6: Pre-Installation

    Floor must be able to support weight of boiler, water and all additional system components. Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation...
  • Page 7: Unpack Boiler

    If using indoor air for combustion (see Venting Section - Indoor Air), avoid operating this boiler in an environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is operated under these conditions, the burner interior and ports must be cleaned and inspected daily to insure proper operation.
  • Page 8: Venting/Air Intake Piping

    III. Venting / Air Intake Piping Do not use this boiler with galvanized, Type 04 or Type 1 stainless steel, non metallic or any other non Al9-4C based vent systems. ® Do not use a barometric damper or drafthood with this appliance.
  • Page 9 (SCG-3 & SCG-4) Disc Air Intake - 4” (SCG-5 & SCG-6) Air Intake - 5” (SCG-7 thru SCG-9) TABlE : BURNhAM VENT SySTEM AND AIR INTAkE SySTEM COMPONENTS Vent System Component Part Number 3” Dia. Pipe x 1 Ft 8116296U 4”...
  • Page 10 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...
  • Page 11 Carefully ensure roundness of cut pipe by hand with gloves before installing. Seal joint with RTV specified in this manual. Install Vent Pipe, Burnham Gasketed Vent System. 1. Procedure for Joining Burnham Gasketed Vent Pipe and Fittings. See Figure 3.
  • Page 12 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 boiler jacket and work towards the air intake terminal. 13. Maintain minimum of ¼ inch per foot slope on horizontal runs.
  • Page 17 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.
  • Page 18 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. adhesive aluminum tape.
  • Page 22 Figure 9: Vertical Air Intake Piping...
  • Page 23 Combination Horizontal Venting System –SCG-3 Through SCG-6 ONLY – See Figures 10 and 11. NOTICE This vent system requires components not supplied with the boiler. Install Combination Vent/Air Terminal. 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.
  • Page 24 RTV (see Figure 3). Install Vent Piping . See Figures 10 and 11. a. Start at vent connector on boiler, see Figure 43 on Page 72, and work towards combination vent/ air terminal. b. Installation of a vertical vent tee 8116304U is required on all vertical vent applications.
  • Page 27 Combination Vertical Venting System – SCG-3 Through SCG-6 ONLY – See Figures 12, 13 and 14. Description Vent Carton Part Number Air Intake Tee Termination Adapter COMBINATION VERTICAl VENT SySTEM COMPONENTS NOTICE This vent system requires components not supplied with the boiler. SCG-3 & SCG-4 100222-01 100224-01 Part Number SCG-5 & SCG-6 100223-01 100225-01...
  • Page 28: Clearances To Combustibles

    system designed for zero clearance installation in residential applications. The inner wall is constructed from superferritic AL29-4C steel. The outer wall is also constructed from stainless steel, providing durability and a lasting finish. 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.
  • Page 29 • For a venting system that extends through any zone above that on which the connected appliance is located (except for one and two family dwellings), the vent system shall be enclosed with an enclosure having a fire resistance rating equal to or greater than that of the floor or roof assemblies through which it passes.
  • Page 30 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.
  • Page 31 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).
  • Page 32 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 (non- concentric) 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.
  • Page 33 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.
  • Page 34 Support Clamp, (4_ _27SS): Support clamps are sold in pairs and can be clamped around the vent and suspended from a rod or cable. They can be used singularly as a saddle clamp to rest the vent in and suspended from two (2) rods or cables. Support Legs Rotated Horizontally: Support legs can be used on horizontal runs by rotating the clamp at the rivet connection.
  • Page 35 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.
  • Page 36 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.
  • Page 37 3 Recommended horizontal installation consists of vent being sloped down away from boiler. See Figure 12. 4. Alternate horizontal installation consists of vent being sloped down toward the boiler. A horizontal vent tee is required.
  • Page 40 Figure 14: Optional Indoor Air - Vent Terminal Installation Figure 15: Indoor Air - Vertical Vent Terminal Installation Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“y”) distance of twelve (1) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation. Figure 1: Indoor Air - Air Intake Terminal Installation...
  • Page 41 ® c. Install maximum of seven (7) 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. ® 90° ® (not required for indoor air).
  • Page 42 Figure 18: Optional Separate horizontal Air 5” Intake Terminal Installation Figure 19: Optional Separate horizontal ” Vent Terminal Installation...
  • Page 43 Figure 0: Optional Separate horizontal 4” Vent Terminal Installation Figure 1: Optional Separate horizontal ” Vent Terminal Installation (Indoor Air)
  • Page 44 Figure : Optional Separate horizontal 4” Vent Terminal Installation (Indoor Air)
  • Page 45: Water Piping And Trim

    Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Burnham’s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
  • Page 46 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.
  • Page 47 . 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.
  • Page 50: Gas Piping

    0% for applications at 10,000 feet above sea levels. De-rate is based on % reduction per 1000 feet. The SCG boiler is available in two () altitude Models: The “S” Model 0 to 4,999 feet above sea level, and the “h” Model 5,000 to 10,000 feet above sea level.
  • Page 51 * 1 CFH of Natural Gas is approximately equal to 1 MBH; 1 CFH of LP is approximately equal to 2.5 MBH; con- tact your gas supplier for the actual heating value of your gas. Connect boiler gas valve to gas supply system. WARNING...
  • Page 52 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...
  • Page 53: Electrical

    “Hot” leg of the power supply. Locate the This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control.
  • Page 55 NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below. Figure 9: Internal Boiler Wiring ladder Diagram...
  • Page 56 The honeywell R8889 Control is available in two three () zone models and two four (4) zone models. Burnham recommends using Model R8889A for three () zone systems and Model R8889B for four (4) zone systems. Models R8889C and R8889D have less load capacity and may not operate with certain types of zone valves.
  • Page 58 NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below.
  • Page 61 Figure 4: Different Manufacturer’s Zone Valve Connections to honeywell R8889...
  • Page 62: Modular Installation

    2. Consult Local Building Codes or National Fuel Gas Code, NFPA 54/ANSI Z222.3 for restrictions and instructions on modular boiler installations. Module Sizing Burnham recommends sizing each boiler in a modular system to provide 20 % of the combined heating load where ever possible. Venting 1.
  • Page 64: System Start-Up

    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).
  • Page 65 Figure : Operating Instructions...
  • Page 66 Operating Instructions. 1. Follow Operating Instructions to place boiler in operation. See Figure 36. 2. Electronic Ignition Modules with LED indicators. Table 10 cross-references the ignition module terminal designations to the ignition terminal Figure 7: lED locations TABlE 11: yEllOW lED FlAME CODES...
  • Page 67 TABlE 1: GREEN lED STATUS CODES Green LED Flash Code Indicates (X + Y) No “Call for Heat” Startup - Flame sense Flash Fast calibration Heartbeat Normal operation 5 minute Retry Delay- Pilot flame not detected during trial for ignition Recycle- Flame failed during run Flame sensed out of...
  • Page 68 honeywell Electronic Ignition Troubleshooting Guide Figure 8: Troubleshooting Guide...
  • Page 69 Figure 39: Sequence of Operation Sequence of Operation. See Figure 39. If boiler fails to operate properly, see Troubleshooting Tree in Section IX: Service. Check pilot burner flame. See Figure 41. Flame should be steady, medium hard blue enveloping 3/8 to ½...
  • Page 70 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.
  • Page 71: Service

    Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service. Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, remove or tamper with any control device.
  • Page 72 SCG-6 SCG-7 SCG-8 SCG-9 * Main burners numbered left to right as viewed from front of boiler. Figure 4: Silicone Tubing Assembly 13. Install Jacket Top Rear Panel. 14. Connect Vent System. See Figure 43. 15. Connect Blower Motor Wiring Harness.
  • Page 74 NOTE: If switch drops-out before boiler reaches temperature or if pressure differential readings are below minimums shown in Table 15, check for cracks in hose or contact your nearest Burnham representative. to differential pressure switch. See Figures 42 and 5,000 - 10,000 Ft. Elevation .80”...
  • Page 75 ThIS PAGE lEFT INTENTIONAlly BlANk...
  • Page 78: 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...
  • Page 79 Description SCG-3 1. CASTING ASSEMBly Section Assembly 61707031 Left End Section Center Section 71707003 Right End Section Slip Nipple, #3 806600009 Flue Gas Baffle 71107002 Tie Rod, ¼” -20 100109-01 Hex Nut, ¼” -20 [Quantity] Part Number SCG-4 SCG-5 61707041 61707051 71707003 71707003...
  • Page 81 Description . BASE ASSEMBly Base Wrapper Base Tray Burner Tray Assembly Base Front Panel Burner Access Panel Cerafelt Gasket 1/2” x 2” Cerafelt Gasket 1/2” x 2” Base Side Insulation Base Rear Insulation Base Front Insulation Base Leg Assembly Self Tapping Screw, 1/4” -20 x 1/2” Flame Roll-out Switch Sheet Metal Screw, #8 x 3/4”...
  • Page 83 Description . BASE ENClOSURE ASSEMBly Air Box Assembly Air Box Door Combustion Air Diffuser Pilot Tube Gasket Cover Plate Pilot Tube Gasket Window Plug Sheet Metal Screws #8 x 1/2” Self Tapping Screw, 10-32 x 3/8” [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6...
  • Page 85 Description 4. FAN/CANOPy ASSEMBly Canopy Assembly - Sea Level Canopy Assembly - High Altitude Cerafelt U-Clip Sheet Metal Screw, #10 x 1” Fan Gasket Lock Washer, #10 Machine Screw, #10-24 x 2½” [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 61107031 61107041 61107051 61107061 61107071 61107081 61107091 61107032 61107042 61107052 61107062 61107072 61107082 61107092 9206005 (4) 80861512...
  • Page 87 Description 5. BURNER ASSEMBlIES Gas Valve (Natural Gas), Honeywell VR8204P1171 Gas Valve (Natural Gas), Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell VR8204C3015 Gas Valve (LP Gas), Honeywell VR8304P4280 Nipple, ½” NPT x Close Nipple, ¾” NPT x Close Union, ½” NPT Union, ¾”...
  • Page 89: Control Panel Assembly

    Description . CONTROl PANEl ASSEMBly Limit, Honeywell L4080D Transformer/Relay, Honeywell R8285D Ignition Module, Honeywell S8670E3003 Blower Relay, Honeywell R8222U1006 Differential Pressure Switch Sea Level 0’ - 4999’ High Altitude - 5000’ - 10,000’ Junction Box [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 100189-01...
  • Page 91 7. JACkET PARTS Jacket Left Side Panel Jacket Right Side Panel Rear Panel Vestibule Panel Top Panel Front Door Air Intake Collar Assembly Handle Door Clip Bushing Burnham Logo [Quantity] Part Number SCG-3 SCG-4 SCG-5 60407033 60407043 60407053 60407034 60407044 60407054...
  • Page 92 Description 8. MISCEllANEOUS PARTS CARTON Water Manifold Temperature/Pressure Gauge Circulator Wiring Harness Safety Relief Valve Boiler Drain Valve Vent Terminal Air Intake Terminal Vent Connector [Quantity] Part Number SCG-3 SCG-4 SCG-5 8110701 6116045 6116044 8110703 SCG-6 SCG-7 SCG-8 80607001 8056169...
  • Page 93 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
  • Page 94: Service Record

    SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 95 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 96: Limited Warranty

    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.

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