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Burnham SCG, Installation & Service Instructions Manual

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Burnham SCG Installation & Service Instructions Manual Download Page 58

58

Figure 

1:  Single Zone System with Packaged 

Alliance™ W

ater 

h

eater W

iring Schematic

NOTICE

If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing 

below.

Summary of Contents for SCG

Page 1: ...I V R E S G C S R E L I O B D E R I F S A G n o n o i t a m r o f n i g n i k e e s n e h W r o t c a r t n o c g n i t a e h r u o y l l a c r e l i o b o t s r i a p e r r o e c i v r e s r o F l e...

Page 2: ...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 Mass...

Page 3: ...boiler is inoperative This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the...

Page 4: ...rances to Combustibles I Pre Installation 6 II Unpack Boiler 7 III Venting Air Intake Piping 8 IV Water Piping and Trim 45 V Gas Piping 50 VI Electrical 53 VII Modular Installation 62 VIII System Star...

Page 5: ...Figure 2 Dimensions...

Page 6: ...nts from water dripping spraying rain etc during boiler operation and service circulator replacement condensate trap control replacement etc I Pre Installation F Provide combustion and ventilation air...

Page 7: ...should be undertaken only by trained and skilled personnel from a qualified service agency E Tilt the boiler to its front side or back side and slide a wooden slat under the three raised feet F Tilt...

Page 8: ...al Vent Kit Required Part Number Installation Drawing and Specification See Section 1 Separate Horizontal Direct Vent sealed combustion with both the vent pipe and air intake pipe terminating horizont...

Page 9: ...able 100179 01 3 Dia 90 Elbow 8116294U 5 4 Dia 90 Elbow 100180 01 3 Dia 45 Elbow 8116292U 5 4 Dia 45 Elbow 100181 01 3 Dia Horizontal Drain Tee 8116302U 2 4 Dia Horizontal Drain Tee 100182 01 3 Dia Ve...

Page 10: ...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...

Page 11: ...oor 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 Pl...

Page 12: ...Figures 4A 4B 5A and 5B 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...

Page 13: ...13 Figure 4A Recommended Separate Horizontal Vent Air Intake Installation...

Page 14: ...14 Figure 4B Alternate Separate Horizontal Vent Air Intake Installation...

Page 15: ...15 Figure 5A Separate Horizontal Vent Air Intake Terminal Configuration SCG 3 thru 7...

Page 16: ...16 Figure 5B Separate Horizontal Vent Air Intake Terminal Configuration SCG 8 and 9...

Page 17: ...ent 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...

Page 18: ...rtight seal e All exposed air intake piping must be constructed of corrosion resistant material such as aluminum stainless steel or PVC 15 Seal all joints airtight using silicone caulk or self adhesiv...

Page 19: ...19 Figure 7 Attic Offset Figure 6 Vertical Vent Installation...

Page 20: ...Termination 3 Vent Terminal 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 f...

Page 21: ...Termination 4 Vent Terminal Extend Vent Air Intake Piping to maintain minimum vertical X and minimum horizontal Y distance of twelve 12 inches from roof surface Allow ad ditional vertical X distance...

Page 22: ...22 Figure 9 Vertical Air Intake Piping...

Page 23: ...y 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 NOTICE This vent system requires components not sup...

Page 24: ...erminal and pipe with locking band and seal with RTV see Figure 3 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...

Page 25: ...25 Figure 10 Combination Horizontal Vent Air Installation SCG 3 thru 6...

Page 26: ...26 Figure 11 Combination Horizontal Vent Air Terminal Installation SCG 3 thru 6...

Page 27: ...3 and 14 NOTICE This vent system requires components not supplied with the boiler Description Part Number SCG 3 SCG 4 SCG 5 SCG 6 Vent Carton Part Number 100222 01 100223 01 Air Intake Tee 100224 01 1...

Page 28: ...A continuous straight line pitch of at least 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 Saf...

Page 29: ...lding 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 th...

Page 30: ...revious 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 insi...

Page 31: ...asured 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 W...

Page 32: ...ealed 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 Con...

Page 33: ...ate 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...

Page 34: ...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 ve...

Page 35: ...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...

Page 36: ...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...

Page 37: ...e and fittings See Figure 3 15 Install supplied air intake terminal See Figure 16 1 Do not exceed maximum vent length Refer to Table 4 Horizontal 2 Maintain minimum inch per foot slope in horizontal r...

Page 38: ...38 Figure 12 Recommended Separate Horizontal Vent Installation...

Page 39: ...39 Figure 13 Alternate Separate Horizontal Vent Installation...

Page 40: ...ing to maintain minimum vertical X and minimum horizontal Y distance of twelve 12 inches from roof surface Allow additional vertical X distance for expected snow accumulation Figure 14 Optional Indoor...

Page 41: ...inal Mounting See Figures 17 18 19 20 21 and 22 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 indoo...

Page 42: ...42 Figure 18 Optional Separate Horizontal Air 5 Intake Terminal Installation Figure 19 Optional Separate Horizontal 3 Vent Terminal Installation...

Page 43: ...43 Figure 20 Optional Separate Horizontal 4 Vent Terminal Installation Figure 21 Optional Separate Horizontal 3 Vent Terminal Installation Indoor Air...

Page 44: ...44 Figure 22 Optional Separate Horizontal 4 Vent Terminal Installation Indoor Air...

Page 45: ...with a hot water boiler IV Water Piping and Trim 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 sa...

Page 46: ...ld 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 AS...

Page 47: ...iping 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 sa...

Page 48: ...48 Figure 25 Recommended Water Piping for Circulator Zoned Heating Systems...

Page 49: ...49 Figure 26 Recommended Water Piping for Zone Valve Zoned Heating Systems...

Page 50: ...of natural gas can be found in Table 6 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 ac...

Page 51: ...and manual shut off valve upstream of boiler gas control valve and outside jacket See Figure 27 1 CFH of Natural Gas is approximately equal to 1 MBH 1 CFH of LP is approximately equal to 2 5 MBH con t...

Page 52: ...d before placing boiler in operation 1 Protect boiler gas control valve For all testing over psig boiler and its individual shutoff valve must be disconnected from gas supply piping For testing at psi...

Page 53: ...k once power is turned off WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm Electrical power may be from more than one source Make sure all pow...

Page 54: ...54 Figure 28 Internal Boiler Wiring Schematic Diagram...

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

Page 56: ...1 zone the first zone of the main control will provide priority circulation If more than four 4 zones are required connect additional R8888 s by wiring the A B and C terminals of each control together...

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

Page 58: ...Figure 31 Single Zone System with Packaged Alliance Water Heater Wiring Schematic NOTICE If an additional system limit is used install in series with the auxiliary limit jumper shown in the drawing be...

Page 59: ...59 Figure 32 Circulator Zoned System Wiring Schematic...

Page 60: ...60 Figure 33 Zone Valve Zoned System Wiring Schematic...

Page 61: ...61 Figure 34 Different Manufacturer s Zone Valve Connections to Honeywell R8889...

Page 62: ...ngth 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 install...

Page 63: ...63 Figure 35 Modular Boiler Gas Piping...

Page 64: ...y piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area 4 Starting with one circuit at a time open zone valve VIII System Start up or shut off valve in system supp...

Page 65: ...65 Figure 36 Operating Instructions...

Page 66: ...ations Perform routine maintenance to assure optimum flame signal 1 Marginal Flame Signal less than 1 1 A System may not operate reliably over time Service call recommended Note This indication may fl...

Page 67: ...5 Vac Control remains in wait mode When the fault corrects control resumes nor mal operation after one minute delay Check transformer and AC line for proper input voltage to the control Check with fu...

Page 68: ...68 Figure 38 Troubleshooting Guide Honeywell Electronic Ignition Troubleshooting Guide...

Page 69: ...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 pilot lead wires from g...

Page 70: ...under firing of the appliance Improper and unsafe boiler operation may result 4 Determine Input Rate Multiply gas flow rate by gas heating value 5 Compare measured input rate to input rate stated on r...

Page 71: ...d 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...

Page 72: ...oosen the 4 screws from Canopy 7 Remove Flue Gas Baffles Inspect Flue Gas Baffles for deterioration 8 Inspect flue passages Clean with flue brush See Figure 44 9 Inspect heating surface in combustion...

Page 73: ...73 Figure 44 Flue and Burner Cleanout 1 Burner...

Page 74: ...Door must be installed F Check operation Follow steps G through P from Section VIII System Start up G Procedure for Measuring Differential Pressure See Figure 45 1 With boiler off remove Gray and Bla...

Page 75: ...75 THIS PAGE LEFT INTENTIONALLY BLANK...

Page 76: ...76...

Page 77: ...77...

Page 78: ...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...

Page 79: ...1 71707003 2 71707003 3 71707003 4 71707003 5 71707003 6 71707003 7 71707003 1C Right End Section 71707002 1D Slip Nipple 3 4 806600009 6 806600009 8 806600009 10 806600009 12 806600009 14 806600009...

Page 80: ...80...

Page 81: ...er Access Panel 71807036 71807046 71807056 71807066 71807076 71807086 71807096 2F Cerafelt Gasket 1 2 x 2 9206003 2G Cerafelt Gasket 1 2 x 2 9206003 2H Base Side Insulation 2 72007001 2J Base Rear Ins...

Page 82: ...82...

Page 83: ...61807082 61807092 3B Air Box Door 71807034 71807044 71807054 71807064 71807074 71807084 71807094 3C Combustion Air Diffuser N A 71807049 71807059 71807069 71807079 71807089 71807099 3D Pilot Tube Gask...

Page 84: ...84...

Page 85: ...07031 61107041 61107051 61107061 61107071 61107081 61107091 Canopy Assembly High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092 4B Cerafelt 9206005 4C U Clip 4 80861512 4D She...

Page 86: ...86...

Page 87: ...Union NPT 806604023 N A Union NPT N A 806604001 5D Gas Manifold 82207031 82207041 82207051 82207061 Gas Manifold 82207071 82207081 82207191 5E Burner Orifices Natural Gas 47 4 822710 6 822710 8 82271...

Page 88: ...88...

Page 89: ...89 01 6B Transformer Relay Honeywell R8285D 80160155U 6C Ignition Module Honeywell S8670E3003 100959 01 6D Blower Relay Honeywell R8222U1006 80160096U 6E Differential Pressure Switch Sea Level 0 4999...

Page 90: ...90...

Page 91: ...7063 60407073 60407083 60407093 7D Vestibule Panel 60407034 60407044 60407054 60407064 60407074 60407084 60407094 7E Top Panel 60407032 60407042 60407052 60407062 60407072 60407082 60407092 7F Front D...

Page 92: ...ous Parts Carton 8A Water Manifold 80607001 8B Temperature Pressure Gauge 8056169 8C Circulator Wiring Harness 6130701 8D Safety Relief Valve 81660363 8E Boiler Drain Valve 806603061 8F Vent Terminal...

Page 93: ...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 separatel...

Page 94: ...94 SERVICE RECORD DATE SERVICE PERFORMED...

Page 95: ...95 SERVICE RECORD DATE SERVICE PERFORMED...

Page 96: ...sorting 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 Limited Warranty FOR RESIDENTIAL CAST IRON WATER...

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