Burnham SCG 1100-H4 User Manual

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STAR® guidelines for energy efciency established by the United States Environmental Protection Agency (EPA).

®

Partner, Burnham Hydronics has determined that the SCG meets the ENERGY

8140705R9-10/08

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 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.

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.

DANGER

Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.

Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.

Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.

CAUTION

NOTICE

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.
If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use

any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas

supplier’s instructions or if the supplier is unavailable, contact the re department.

2

WARNING

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal

injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an experienced, skilled, and
knowledgeable installer or service agency.

This boiler must be properly vented.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season

and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life

to vent safely and will contribute toward maintaining the boiler’s efciency.

Installation is not complete unless a pressure relief valve is installed into the tapping located on top of
appliance. - See the Water Piping and Trim Section of this manual for details.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt

to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.

Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instruc-

tions, including all those contained in component manufacturers manuals which are provided with the
boiler before installing, starting up, operating, maintaining or servicing.

Keep boiler area clear and free from combustible materials, gasoline and other ammable vapors or
liquids.

All cover plates, enclosures and guards must be in place at all times.

NOTICE

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.

3

Table of Contents

I. Pre-Installation ...............................6

II. Unpack Boiler ................................

III. Venting/Air Intake Piping ..............

IV. Water Piping and Trim .................

V. Gas Piping ....................................

45

50

VI. Electrical .......................................53

7

8

VII. Modular Installation ....................

VIII. System Start-up ............................

IX. Service .......................................... 71

X. Repair Parts ..................................

62

64

78

Figure 1: Minimum Clearances to Combustibles

4

Figure 2: Dimensions

5

I. Pre-Installation

WARNING

If you do not follow these instructions exactly,

a re or explosion may result causing property

damage or personal injury.

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 or Propane Installation Code,

CAN/CSA-B149.1.

DANGER

Do not install boiler where gasoline or other

ammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners, chemicals,
sprays, paint removers, fabric softeners, etc.) are
used or stored.

NOTICE

Due to the low water content of the boiler, mis­sizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Burnham
DOES NOT warrant failures caused by mis-sized
boiler applications. DO NOT oversize the boiler to
the system. Modular boiler installations greatly
reduce the likelihood of boiler oversizing.

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/
CSA B149.1 Installation Codes.

B. Appliance is design certied for installation on

combustible ooring. Do not install boiler on

carpeting.

C. Provide clearance between boiler jacket and

combustible material in accordance with local re

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 oor. For basement installation provide

solid base such as concrete, if oor is not level or if
water may be encountered on oor 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.).

WARNING

Adequate combustion and ventilation air must

be provided to assure proper combustion.

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 unconned
space.

b. If result is less than 50 ft³ per 1,000 Btuh, space

is considered a conned 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

oors, between wall-ceiling joints, between wall

panels, at plumbing and electrical penetrations,
and at other openings.

5. For boiler located in an unconned space in a
building of other than unusually tight construction,
adequate combustion and ventilation air is normally

provided by fresh air inltration through cracks

around windows and doors.

6

NOTICE

Boilers operated with direct vent (sealed
combustion) are exempt from needing provisions
for combustion air from the room, provided
air intake piping is installed per Code and the
instructions in the manual.

6. For boiler located within

of unusually tight construction or within conned
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.

unconned space in building

c. Horizontal ducts. Minimum free area of one (1)

square inch per 2,000 Btu per hour input of all
equipment in space. Duct cross-sectional area
shall be same as opening free area.

Alternate method for boiler located within

conned space. Use indoor air if two permanent

openings communicate directly with additional

space(s) of sufcient volume such that combined
volume of all spaces meet criteria for unconned

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 xed in open position or interlocked

with equipment to open automatically before burner
operation. Screens must not be smaller than ¼ inch
mesh.

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 using indoor air for combustion (see Venting Section - Indoor Air), avoid operating this boiler in an

environment where saw dust, loose insulation bers, 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.

II. Unpack Boiler

CAUTION

Do not drop boiler. Do not bump boiler jacket

against oor.

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.

Installation of this boiler should be undertaken
only by trained and skilled personnel from a

qualied 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 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.

WARNING

H. Move boiler to its permanent location.

7

III. Venting / Air Intake Piping

WARNING

Do not use this boiler with galvanized, Type 304 or Type 316 stainless steel, non metallic or any other
non AL29-4C® based vent systems.

Do not use a barometric damper or drafthood with this appliance.
Do not use vent dampers with this boiler.
Moisture and ice may form on surfaces around termination. To prevent deterioration, surfaces should

be in good repair (sealed, painted, etc.).
This appliance needs fresh air for safe operation and must be installed so there are provisions for

adequate combustion and ventilation air.

Do not reduce size of air intake pipe.
Read, understand and follow combustion air instruction restrictions contained in the Pre-Installation

instructions of this manual.
Do not operate appliance where gasoline or other ammable vapors or liquids, or sources of hydro-

carbons (i.e. bleaches, cleaners, chemicals, sprays, paint removers, fabric softeners, etc.) are used,
stored and/or present in the air.

When installing vent pipe through chimney, no other appliance can be vented into the chimney.
Do not exceed maximum vent/air intake lengths. Refer to Table 4.

TABLE 1: AIR INTAKE / VENT SYSTEM OPTIONS

Option Description

Direct Vent (sealed combustion) with both the vent pipe and

1. Separate

Horizontal

2. Separate

Vertical

3. Combination

Horizontal

4. Combination

Vertical

5. Indoor Air

6. Optional

Separate
Horizontal

air intake pipe terminating horizontally (through a sidewall)
with individual penetrations for the vent and air intake piping
and terminals.

Direct Vent (sealed combustion) with both the vent pipe and
air intake pipe terminating vertically (through the roof) with
individual penetrations for the vent and air intake piping and
terminals.

Direct Vent (sealed combustion) with the vent pipe and air

intake pipe joining at a common terminal and terminating

horizontally (through a sidewall up to 15” thick) with only
one penetration.

Direct Vent (sealed combustion) with the vent pipe and air

intake pipe joining at a common terminal and terminating

vertically (through the roof) with only one penetration.

Power Vent - Air used for combustion is provided from within
the building.

Direct Vent (sealed combustion) with both the vent pipe and
air intake pipe terminating horizontally (through a sidewall)
with individual penetrations for the vent and air intake piping
and terminals.

Additional

Vent Kit

Part Number

Required

No See Table 2 D.

No See Table 2 E.

Yes

Yes

No ----- H.

No See Table 2 I.

3 - 6 Section

(61106012)

3 - 4 Section

(100222-01)

5 - 6 Section

(100223-01)

Installation

Drawing and

Specication

(See Section)

F.

G.

8

TABLE 2: VENT SYSTEM COMPONENTS INCLUDED WITH BOILER

Vent System Components Part Number

Gasketed Vent Terminal 3” Horizontal
(SCG-3 thru SCG-7)

Gasketed Vent Terminal 4” Horizontal
(SCG-8 & SCG 9)

Disc Air Intake - 3”
(SCG-3 & SCG-4)

Disc Air Intake - 4”
(SCG-5 & SCG-6)

Air Intake - 5”
(SCG-7 thru SCG-9)

8110701

8110702

6116045

6116044

6116063

TABLE 3: BURNHAM VENT SYSTEM AND AIR INTAKE SYSTEM COMPONENTS

Vent System Component Part Number

3” Dia. Pipe x 1 Ft 8116296U
4” Dia. Pipe x 1 Ft 100176-01
3” Dia. Pipe x 3 Ft 8116298U
4” Dia. Pipe x 3 Ft 100177-01
3” Dia. Pipe x 5 Ft 8116300U
4” Dia. Pipe x 5 Ft 100178-01
3” Dia. Pipe x Adjustable 8116319U

4” Dia. Pipe x Adjustable 100179-01
3” Dia. 90° Elbow 8116294U

4” Dia. 90° Elbow 100180-01
3” Dia. 45° Elbow 8116292U
4” Dia. 45° Elbow 100181-01
3” Dia. Horizontal Drain Tee 8116302U
4” Dia. Horizontal Drain Tee 100182-01
3” Dia. Vertical Drain Tee 8116304U
4” Dia. Vertical Drain Tee 100183-01
3” Single Wall Thimble 8116116
4” Single Wall Thimble 100184-01
3” Double Wall Thimble 8116115
4” Double Wall Thimble 100185-01

Equivalent

Feet of Pipe

1

3

5

Equal to

Installed Length

(1.06 TO 1.64)

5

5

2

7½

---

---

Intake System Components

(Parts by Others)

3”, 4”, or 5” ID Pipe x 1 Ft 1
3”, 4”, or 5” ID Pipe x 2 Ft 2
3”, 4”, or 5” ID Pipe x 4 Ft 4
3”, 4”, or 5” ID Pipe x 5 Ft 5

3”, or 4” 90° Elbow 5
3”, or 4” 45° Elbow 5

5” 90° Elbow 6
5” 45° Elbow 6

* Equivalent Feet of Pipe Based on
Standard 4” Smoke Pipe Design

Equivalent

Feet of Pipe *

TABLE 4: VENT/AIR INTAKE LENGTH

Model

3” Air Intake Pipe

(Equiv. Ft.)

4” Air Intake Pipe

(Equiv. Ft.)

5” Air Intake Pipe

(Equiv. Ft.)

3” Vent Pipe

(Equiv. Ft.)

4” Vent Pipe

(Equiv. Ft.)

Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.

SCG-3 & SCG-4 8 50 --- --- --- --- 8 50 --- --­SCG-5 & SCG-6 --- --- 8 50 --- --- 8 50 --- ---

SCG-7 --- --- --- --- 8 50 8 50 --- ---

SCG-8 & SCG-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

deciencies 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

replace 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 ve (5) minutes of main burner operation. Use
the ame of a match or candle, or smoke from a

cigarette, cigar or pipe.

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, replace dampers and

any other gas burning appliance to their previous
conditions of use.

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.

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 re ofcials 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 conguration all of the air for

combustion is supplied directly to the burner

enclosure from outdoors and ue gases are vented

directly outdoors (through wall or roof). In the

Power Vent conguration, 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 conguration 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 (800­772-0739); Flex-L International Inc. - Star-34 (800­561-1980); Z-Flex U. S., Inc. - Z-Vent (800-654-

5600); and Protech Systems, Inc.- FasNSeal™ (800­766-3473) 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. 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 ve (5) feet. Do not

penetrate any part of the vent system with fasteners.

7. Vent length restrictions are based on equivalent
length of vent/air pipe (total length of straight

pipe plus equivalent length of ttings). Maximum

vent/air lengths are listed in Table 4. Do not exceed
maximum vent/air intake lengths. Table 3 lists

equivalent lengths for ttings. 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 specically

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 ue 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 re resistance rating of at least equal to the
rating of the adjoining oor or ceiling. Maintain

minimum clearances to combustible materials. See
Figure 1.

Note: For one or two family dwellings, re

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 rst

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 sufcient a standard length pipe may be cut

using the procedure outlined below for the Gasket­Less Vent System.

WARNING

Never exceed maximum installed length of 19¾
inches for adjustable length pipe.

Risk of ue gas leakage is possible.

NOTICE

Cut must be square with pipe and led or

sanded smooth before joining. Carefully ensure
roundness of cut pipe by hand with gloves before

installing. Seal joint with RTV specied in this

manual.

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 ue

gases and/or liquid condensate will not escape.

D. Separate Horizontal Venting System. See Figures

4A, 4B, 5A and 5B. See Figure 43 on Page 72 for
Blower Vent Connector Assembly.

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 4A. See Figure 48 for an
alternate horizontal installation.

4. Use appropriate designed thimbles when passing
through combustible walls (thimble use optional for
noncombustible walls). Insert thimble through wall

from outside. Secure outside ange to wall with

nails or screws, and seal ID, OD and vent holes with

sealant material. Install inside ange 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 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 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 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 ve (5) feet

apart on horizontal runs. The complete air intake
piping system must be rigid and able to withstand
minor impacts without collapse.

Inlet air pipe penetration:

15.

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.

Install Air Intake Terminal:

17.

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 ange 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 ange

to provide a weathertight seal.

12

Figure 4A: Recommended Separate Horizontal – Vent/Air Intake Installation

13

14

Figure 4B: Alternate Separate Horizontal – Vent/Air Intake Installation

Figure 5A: Separate Horizontal – Vent/Air Intake Terminal Conguration (SCG-3 thru 7)

15

16

Figure 5B: Separate Horizontal – Vent/Air Intake Terminal Conguration (SCG-8 and 9)

E. Separate Vertical Venting System - See Figures 6, 7, 8A, 8B and 9.

NOTICE

Roof penetrations require the use of roof ashing

and storm collar - not supplied with boiler.

Vertical Venting –

1. See Figure 43 on Page 72 for Blower Vent
Connector Assembly. Do not exceed maximum vent
lengths. Refer to Table 4.

2. Installation of a vertical vent drain tee 8116304U
is required on all vertical vent applications. See
Figures 6 and 7. Attach vertical vent drain tee
directly to elbow or horizontal pipe from an elbow
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 re stops where vent passes through oors,
ceilings or framed walls. The re stop must close

the opening between the vent pipe and the structure.

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.

NOTICE

Vertical venting requires the use of roof ashing

and a storm collar to prevent moisture from
entering the structure.

c. Install storm collar on vent pipe immediately

above ashing. 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 ttings

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 ve (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

ashing and storm collar.
a. Use appropriately designed vent ashing

when passing through roofs. Follow ashing

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 ashing and a storm

collar to prevent moisture from entering the
structure.

17

d. Install storm collar on air intake pipe

immediately above ashing. 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.

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.

18

Figure 7: Attic OffsetFigure 6: Vertical Vent Installation

19

20

Figure 8A: Vertical Vent/Air 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 for expected snow accumulation.

Figure 8B: Vertical Vent/Air 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-

21

ditional vertical (“X”) distance for expected snow accumulation.

22

Figure 9: Vertical Air Intake Piping

F. 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.

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.

1. Do not exceed maximum vent/air intake lengths.
Refer to Table 4.

Vent Carton Part Number 61106012 (Includes Items Below)

Description Component Part Number

A Air Box Sub-Assembly (6” square x 2’ long) 61106011
B Exterior Wall Cover (10” square) 71106016
C 4” x 3” Vent Pipe Reducer 8116239
D Plate-Seal Exterior Cover (2) 71106017
E #8 x ½” Stainless Steel Sheet Metal Screw (19) 80860047
F #10 - 32 x ¼” Stainless Steel Machine Screw (8) 80860842
G #10 - 32 x ½” Aluminum Spacer (4) 80861617

COMBINATION HORIZONTAL VENT SYSTEM COMPONENTS

23

c. From exterior of building, insert air box sub-

assembly into square opening. Push air box

inward until wall ange is against wall, check

for level and mark the location of the four (4)
securing holes on the exterior wall. Remove air
box from wall.

d. Drill four (4) pilot holes, properly sized for the

non-corrosive fasteners (stainless steel, brass, or

aluminum) to be used to secure the wall ange to

the exterior wall. (Securing screws not supplied
with kit.)

e. Attach four (4) 1/2 inch long threaded aluminum

spacers to the outer anges of the exterior
wall ange 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

ange’s back surface to provide a weathertight

seal.

g. Reinstall air box sub-assembly into opening in

exterior wall and secure to wall.

WARNING

Non-corrosive fasteners must be used.

h. Apply a bead of silicone caulk to perimeter of

wall ange, where the wall and ange join. Use
a tool or your nger 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

ange. 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 ange. 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).

Install Vent Piping. See Figures 10 and 11.

3.
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. 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 ve (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 ttings.

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 ttings

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 ve (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.

24

Figure 10: Combination Horizontal – Vent/Air Installation (SCG-3 thru 6)

25

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.

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 100225-01
Termination Adapter 100226-01

COMBINATION VERTICAL VENT SYSTEM COMPONENTS

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

nish.

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.

As a Sealed Combustion system: The unique

3.
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 ue 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,

oors or ceilings as well as maintaining proper
clearances. Be sure to plan a sufcient number

of supports for the entire system that will
maintain the required straight-line pitch and hold

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:

• 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, eld-fabricated vents

or Type B vent sections must not be used. Do

not mix pipes, ttings, 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, oors or walls must
be properly re-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

bers, or other materials that are capable of

being ignited or burned. Such material shall be

considered combustible even though it is ame­proofed, re-retardant, or plastered. (Source:

NFPA54/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: NFPA54/
ANSI Z223.1-1999.)

CLEARANCES TO COMBUSTIBLES:

Clearance to

Diameter

Combustible

Material

0”

3” - 4”

1” 400
0” 400
1” 550
0” 550 Any Noncombustible material

28

Maximum Flue

Gas Temp. (°F)

550

Orientation Enclosure

Vertical, No

Offsets

Horizontal,

Vertical with

Offsets

Fully enclosed by combustible material on all
sides330

Unenclosed, at least 1 side open, combustible
material on a maximum of 3 sides

• For a venting system that extends through
any zone above that on which the connected
appliance is located (except for one and two
family dwellings), the vent system shall be

enclosed with an enclosure having a re

resistance rating equal to or greater than that of

the oor or roof assemblies through which it

passes.

• Design any 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 ue collar to the termination
shall not exceed that specied 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 ttings together, use an alcohol pad to wipe the joint area of both ends of the inner

pipe. This will remove any foreign matter which may affect the integrity of the seal. Install the system with the

female ends (ends with the red seal) pointing away from the appliance. (Unless specied 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 rmly 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.

NOTICE

Do not overtighten. If using a variable torque drill, use a low torque setting to install screws, as not to strip
out the holes. If a hole becomes stripped due to overtightening, a larger diameter screw (½” long max.) or
short pot rivet can be used.

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

An effective way of marking is to run a length of tape

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).

around the section, assuring a square cut.

e. Add

The inner pipe is always cut 1” longer than the

f.

g. Reassemble the inner vent into the outer jacket and

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).

outer pipe.

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.

reinstall the snap ring into the groove. Push the
inner vent into the outer jacket until the triangle on

the inner vent is seated rmly 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 rmly. 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 (non-

concentric) air intake and ue exhaust collars. The male end

of the tee connects to EZ Seal appliance adapters and the tee
takeoff/snout connects to the 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 specied 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).

Condensate Drains:

10.

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 tting as close to the
appliance ue 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 tting 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. oor 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 nal 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 restop, 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 restop to
the structure at the four (4) corners. Install the vent section through the restop 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 at (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

roong 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. Position weld seams in vent pipes,
in all horizontal runs, at the top to avoid condensate
from lying on the seams.

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. See Figure 13.

5. Use appropriately designed thimbles when passing
through combustible walls (thimble use optional
for noncombustible walls). Insert thimble through

wall from outside. Secure outside ange to wall

with nails or screws, and seal with sealant material.

Install inside ange 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.

Vertical –

10. Installation of a vertical vent drain tee 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 re stops where vent passes through oors,
ceilings or framed walls. The re stop must close

the opening between the vent pipe and the structure.
Fire stop manufacturers are Air-Jet, American Metal
Products, Metal-Fab, and Simpson Dura-Vent.

12. Whenever possible install vent straight through roof.
Refer to Figure 6. Maintain minimum clearance to
combustible materials. For attic offset see Figure 7.

13. Install Vent Terminal.
a. Size roof opening to maintain minimum

clearance from combustible materials.

b. Use appropriately designed vent ashing

when passing through roofs. Follow ashing

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 ashing and a storm

collar to prevent moisture from entering the
structure.

e. Install storm collar on vent pipe immediately

above ashing. Apply Dow Corning Silastic 732

RTV Sealant between vent pipe and storm collar
to provide weathertight seal.

f. Attach vent terminal.

Vent Terminal and Air Intake Terminal –

14. Join vent terminal to 45° elbow (supplied by
installer). Join 45° elbow/terminal assembly to vent
pipe. Refer to Section C for proper procedures for

joining vent pipe and ttings. See Figure 3.

15. Install supplied air intake terminal. See Figure 16.

37

38

Figure 12: Recommended Separate Horizontal - Vent Installation

Figure 13: Alternate Separate Horizontal - Vent Installation

39

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
(12) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.

40

Figure 16: Indoor Air - Air Intake Terminal Installation

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 seven (7)
feet vertical exterior run of the vent/air intake piping
to be installed on separate horizontal venting and
indoor air horizontal venting.

NOTICE

Exterior run to be included in equivalent vent/air

intake lengths.

3. Install vent piping.

a. Install vent piping for desired venting system.

Refer to specic 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 seven (7) feet of AL 29-4C

vent pipe. Refer to Sections C through E for proper

procedures for joining vent pipe and ttings.

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 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 specic 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 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.

Figure 17: Optional Separate Horizontal Air 3” or 4” Intake Terminal Installation

41

Figure 18: Optional Separate Horizontal Air 5” Intake Terminal Installation

42

Figure 19: Optional Separate Horizontal 3” Vent Terminal Installation

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

WARNING

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

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.

A. Design and install boiler and system piping to

prevent oxygen contamination of boiler water and
frequent water additions.

1. There are many possible causes of oxygen
contamination such as:

a. Addition of excessive make-up water as a result

of system leaks.

b. Absorption through open tanks and ttings.

c. Oxygen permeable materials in the 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 ttings 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.

B. Low Water Cut Off (LWCO) on Hot Water Boilers

(Optional)

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 100592-01) 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.

WARNING

DO NOT ATTEMPT to cut factory wires to
install an aftermarket Low Water Cut Off

(LWCO). Only use connections specically
identied for Low Water Cut Off.

In all cases, follow the Low Water Cut Off
(LWCO) manufacturer’s instructions.

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 oor level as the boiler). In

addition, some jurisdictions require the use of a LWCO
with a hot water boiler.

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
draining the heating system. Many probe LWCO
manufacturers recommend an annual inspection of the
probe.

45

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 100592-01) 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 lling the system.

The boiler should attempt to operate once the water
level is above the LWCO.

NOTICE

Ensure the location of the LWCO in the piping will
allow for connection of the LWCO wiring harness
to the factory wiring of the SCG.

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.

WARNING

Pressure relief valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut-off
valves, plugs or caps. Consult Local Codes for
proper discharge piping arrangement.

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.

NOTICE

Burnham recommends sizing the system

circulator to supply sufcient ow (GPM) to allow a

20°F temperature differential in the system. When
sizing the system circulator, the pressure drop of
all radiators, baseboard and radiant tubing and all
connecting piping must be considered.

D. Install circulator with anges, gaskets and bolts

provided. Circulator harness allows circulator to be
mounted on supply or return. Connect harness to
circulator and secure any excess conduit.

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.

Figure 23: Recommended Piping for Combination

Heating & Cooling (Refrigeration) System

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

ow control valves to prevent gravity circulation of

boiler water during operation of cooling system.

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.).

46

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 ow 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 ushed. A local qualied 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

ushed, and before relling 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 rst 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 rst 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

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

49

V. Gas Piping

WARNING

Failure to properly pipe gas supply to boiler may
result in improper operation and damage to the
boiler or structure. Always assure gas piping is
absolutely leak free and of the proper size and
type for the connected load.

An additional gas pressure regulator may be
needed. Consult gas supplier.

A. Size gas piping. Design system to provide adequate gas

supply to boiler. Consider these factors:

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.

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).

3. Length of piping and number of ttings. Refer to

Table 7 for maximum capacity of Schedule 40 pipe.
Table 8 lists equivalent pipe length for standard

ttings.

4. Corrections for the specic gravity 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 acceptable to authority having jurisdiction.

TABLE 6: SPECIFIC GRAVITY CORRECTION
FACTORS FOR NATURAL GAS

Specic

Gravity

--- --- 0.85 0.81

--- --- 0.90 0.82

0.60 1.00 1.00 0.78

0.65 0.96 1.10 0.74

0.70 0.93 1.20 0.71

0.75 0.90 1.30 0.68

0.80 0.87 1.40 0.66

Correction

Factor

Specic

Gravity

Correction

Factor

TABLE 5: GAS RATINGS

Boiler
Model

Number

SCG-3
SCG-4

SCG-5

SCG-6

SCG-7

SCG-8

SCG-9

Natural/LP

Maximum

Gas Pressure

(in. w.c.)

14 4.5 11.5 3.5 10.5

Minimum Natural

Gas Pressure

(in. w.c.)

Inlet to Gas Valve

Minimum LP

Gas Pressure

(in. w.c.)

Inlet to Gas Valve

Natural

Manifold

Pressure

(in. w.c.)

LP

Manifold

Pressure

(in. w.c.)

NOTICE

SCG boilers built for altitudes greater than 4,999 feet above sea level need to be specially oriced to adjust for
changes in atmospheric conditions. The SCG boiler “H” Model has been certied to operate in atmospheric

conditions from 5,000 to 10,000 feet above sea level. Input is de-rated by 10% for applications at 5,000 feet
above sea level, and 20% for applications at 10,000 feet above sea levels. De-rate is based on 2% reduction
per 1000 feet.

The SCG boiler is available in two (2) 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.

For applications above 10,000 feet, consult the manufacturer.

50

TABLE 7: MAXIMUM CAPACITY OF SCHEDULE 40 PIPE IN CFH* FOR NATURAL GAS PRESSURES
OF 0.5 PSIG OR LESS

Length

[Feet]

10 132 278 520 1,050 175 360 680 1,400
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 56 115 215 440 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 57 118 220 460
90 40 84 160 320 53 110 205 430

100 38 79 150 305 50 103 195 400

0.3 Inch w.c. Pressure Drop 0.5 Inch w.c. Pressure Drop

½ ¾ 1 1¼ ½ ¾ 1 1¼

* 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.

WARNING

Failure to use proper thread compounds on all

gas connectors may result in leaks of ammable

gas.

WARNING

Gas supply to boiler and system must be
absolutely shut off prior to installing or servicing
boiler gas piping.

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 liqueed 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

VALVES FULLY OPEN

Pipe
Size

½” 06.22 0.35 18.6 9.3 4.3 1.6 0.78 1.0 3.1
¾” 0.824 0.44 23.1 11.5 5.3 2.1 0.97 1.4 4.1

1” 1.049 0.56 29.4 14.7 6.8 2.6 1.23 1.8 5.3

1¼” 1.380 0.74 38.6 19.3 8.9 3.5 1.60 2.3 6.9

I.D.

Inches

Gate Globe Angle

Swing

Check

90°

Elbow

45°

Elbow

90° Tee, Flow

Through Run

90° Tee, Flow

Through Branch

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

piping by closing boiler’s individual manual shutoff
valve.

2. Locate leaks using approved combustible gas

detector, soap and water, or similar nonammable

solution.

DANGER

Do not use matches, candles, open ames or

other ignition source to check for leaks.

52

VI. Electrical

DANGER

Positively assure all electrical connections are unpowered before attempting installation or service of
electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock
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 power is off before attempting any

electrical work.
Each boiler must be protected with a properly sized over-current device.

Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with

a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls
used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

A. General. Install wiring and electrically ground boiler

in accordance with authority having jurisdiction or, in
the absence of such requirements, follow the National
Electrical Code, NFPA 70, and/or CSA C22.1 Electrical

Code.

B. A separate electrical circuit must be run from

the main electrical service with an over-current
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.

NOTICE

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. Certain Local Codes require an additional water temperature limit. In addition, certain types

of systems may operate at temperatures below the minimum set point of the limit contained in the boiler.

If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat) located in the system

piping as shown in the Water Piping and Trim Section of this manual. Wire as indicated in the Electrical
Section of this manual.

NOTICE

All wire, wire nuts, controls etc. are installer supplied unless otherwise noted.

53

54

Figure 28: Internal Boiler Wiring Schematic Diagram

NOTICE

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

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.
Single Zone Heating System – Refer to Figure 30 of this manual for the electrical diagram for this type of system.

5.

Set the thermostat heat anticipator to 0.60 amps.

Single Zone Heating System with Alliance™ Water Heater - Refer to Figure 31 of this manual for the electrical diagram

6.

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.

NOTICE

The Honeywell R8888 Control is available in a three (3) zone Model (R8888A) and a four (4) zone Model
(R8888B). Up to four (4) R8888’s may be used together to provide control for up to twelve (12) individual

zones. Only one (1) zone, the rst 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. Each R8888 requires a 120 volt power supply. If more than one (1) R8888 is used, set the panel
type switch to “main” on the rst R8888 and set the panel type switch to “expansion” on the second, third

or fourth R8888.

Conventional Zone Valve Zoned System – Refer to Figure 33. Wiring to the most popular models of zone valves is given

8.

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.

NOTICE

The Honeywell R8889 Control is available in two three (3) zone models and two four (4) zone models.
Burnham recommends using Model R8889A for three (3) 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. Up to four (4) R8889’s may be used together to provide up to sixteen (16) individual zones.

Only one (1) zone, the rst zone of the main control will provide priority zoning for the Alliance indirect
water heater. If more than four (4) zones are required, connect additional R8889’s by wiring the A, B and
C terminals of each control together. Each R8889 requires a 120 volt power supply. If more than one (1)
R8889 is used, set the panel type switch to “main” on the rst R8889 and set the panel type switch to

“expansion” on the second, third or fourth R8889.

56

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

57

NOTICE

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

58

Figure 31: Single Zone System with Packaged Alliance™ Water Heater Wiring Schematic

Figure 32: Circulator Zoned System Wiring Schematic

59

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.

WARNING

Do not manifold vent pipes together.

2. The maximum vent length for each boiler is fty

(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.

CAUTION

Installing multiple vent terminations close
together promotes frost buildup on buildings. To
minimize this possibility, extend the distance from
the building to the end of the vent termination
and increase the horizontal distance between
terminations.

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

fty (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
with vertical venting and sidewall combustion air

62

inlet (or visa versa) if installation conditions do not
allow alternate arrangement.

TABLE 9: MODULAR BOILER WATER
MANIFOLD SIZING

Combined Output

(MBH)

< 166 1¼”
< 260 1½”
< 550 2”
< 900 2½”

< 2000 3”

Recommended Minimum

Common Water Manifold

Size (NPT)

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.

WARNING

If gas pressure in the building is above ½ psig,

an additional gas pressure regulator is required.

Using one additional regulator for multiple
boilers may result in unsafe boiler operation.
The additional regulator must be able to properly
regulate gas pressure at the input of the smallest
boiler. If the regulator cannot do this, two or

more additional regulators are required. Consult

regulator manufacturer and/or local gas supplier

for instructions and equipment ratings.

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.

Figure 35: Modular Boiler Gas Piping

63

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 specied 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. Conrm all electrical, water and gas supplies are

turned off at the source and that vent is clear of
obstructions.

D. Conrm that all manual shut-off gas valves between

the boiler and gas source are closed.

WARNING

Completely read, understand and follow all
instructions in this manual before attempting
start up.

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 lling.

WARNING

The maximum operating pressure of this boiler
is 30 psig. Never exceed this pressure. Do not
plug or change pressure relief valve.

NOTICE

If it is required to perform a long term pressure

test of the hydronic system, the boiler should

rst 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 rst 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.

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 ve gallon bucket at a
suitable oor drain or outdoor area).

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 ll 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 overow 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 lling the system until the
pressure gauge reads 12 psi. Close ll valve.

(Note - If make-up water line is equipped with

pressure reducing valve, system will automatically

ll to 12 psi. Follow ll valve manufacturer’s

instructions).

10. Open isolation valve in boiler supply piping.

11. Remove hose from hose bib.

F. Conrm 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-red appliances.

4. Turn on gas supply to the boiler gas piping.

5. Conrm 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 eld 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.

DANGER

Do not use matches, candles, open ames or

other ignition source to check for leaks.

8. Purge gas line of air.

64

Figure 36: Operating Instructions

65

H. 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

numbers in the wiring ladder diagrams. The yellow

LED indicates the status of the ame, see Table 11.

The green LED indicates the status of the system,
see Table 12. See Figure 37 for LED locations. See
Figure 38 for Troubleshooting Guide.

TABLE 10: IGNITION MODULE TERMINAL
CROSS-REFERENCE

Ignition Module

Terminal Designation

MV 1

MV/PV 2

PV 3

GND 4

24V (GND) 5

24V 6

Figure 37: LED Locations

TABLE 11: YELLOW LED FLAME CODES

Yellow LED

Flash Code

a

Indicates Recommended Service Action

SPARK 9

Heartbeat Normal Flame Signal N/A

Weak Flame Signal ­System will operate reliably but ame signal is

2

less than desired.
Note: This indication may ash temporarily

during or shortly after lightoff on some appli-

cations.

System may not operate reliably over time.

1

Service call recommended.
Note: This indication may ash temporarily

during or shortly after lightoff on some appli-

cations.

OFF

operation.

a

Flash Code Descriptions

Marginal Flame Signal (less than 1.1 µA) -

No Flame or Flame Signal -

below minimum threshold for system

Perform routine maintenance to

assure optimum ame signal.

Check gas supply, pilot burner, ame
sense wiring, contamination of ame
rod, burner ground connection.

Wiring Ladder Diagram

Terminal Number

N/A

66

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- The ash code number signies that the LED ashes X times at 2Hz, remains off for two
seconds, and then repeats sequence.

TABLE 12: GREEN LED STATUS CODES

Green LED

Flash Code

(X + Y)

Flash Fast

Heartbeat Normal operation N/A None

a

Flash Code Descriptions:

a

OFF No “Call for Heat” N/A None

Startup - Flame sense

calibration

5 minute Retry Delay-

2

3

4

7

8

6 + 2

6 + 3

6 + 4

ON

- Flash Fast: rapid blinking

- Heartbeat: Constant ½ second bright, ½ second dim cycles.

- A single ash code number signies that the LED ashes X times at 2Hz, remains off for two seconds, and then

- X + Y ash codes signify that the LED ashes X times at 2Hz, remains off for two seconds, ashes Y times at 2

Pilot ame not detected

during trial for ignition

Recycle- Flame failed
during run

Flame sensed out of
sequence

Flame sense leakage to
ground

Low secondary voltage
supply- (below 15.5 Vac)

5 minute Retry Delay­On every third retry on
same “Call for Heat”

On every 6th ame

failure during run on the

same “Call for Heat”

Flame sensed out of
sequence- longer than

10 seconds

Soft lockout due to error
detected during self
check sequences

repeats the sequence.

Hz, remains off for three seconds, and then repeats the sequence.

Indicates Next System Action Recommended Service Action

N/A None

If system fails to light on next trial

for ignition check gas supply, pilot

Initiate new trial for ignition after retry

delay completed.

Initiate new trial for ignition. Flash

code will remain through the ignition

trial until ame is proved.

If situation self corrects within 10

seconds, control returns to normal

sequence. If ame out of sequence re­mains longer than 10 seconds, control
goes to Flash code 6+4 (see below)

Control remains in wait mode. When

the fault corrects, control resumes nor-

mal operation after a one minute delay.

Control remains in wait mode. When

the fault corrects, control resumes nor-

mal operation after one minute delay.

Initiate new trial for ignition after retry

delay completed.

5 minute retry delay, then initiate new
trial for ignition.

Control waits until ame is no longer
sensed and then goes to soft lockout.
Flash code continues. Control auto
resets from soft lockout after one hour.

Control auto resets from soft lockout

after one hour.

burner, spark and ame sense wir­ing, ame rod contamination or out
of position, burner ground connec­tion.

If system fails to light on next trial

for ignition check gas supply, pilot

burner, ame sense wiring, ame
rod contamination, burner ground
connection.

Check for pilot ame. Replace gas
valve if pilot ame present. If no
pilot ame, cycle “Call for Heat.” If
error repeats, replace control.

Check ame sense lead wire for
damage or shorting. Check that
ame rod is in proper position.
Check ame rod ceramic for cracks,
damage or tracking.

Check transformer and AC line for

proper input voltage to the control.

Check with full system load on the

transformer.
Check gas supply, pilot burner, spark

and ame sense wiring, ame rod

contamination or out of position,

burner ground connection.
Check gas supply, pilot burner, ame

sense wiring, contamination of ame
rod, burner ground connection.

Check for pilot ame. Replace gas
valve if pilot ame present. If no
pilot ame, cycle “Call for Heat.” If
error repeats, replace control.

Reset by cycling “Call for Heat.” If

error repeats, replace the control

67

Honeywell Electronic Ignition Troubleshooting Guide

68

Figure 38: Troubleshooting Guide

Figure 40: 1 Inch Main Burner ame

Figure 41: Pilot Burner Flame

tipping. Orange-yellow streaks should not be confused
with true yellow tipping.

Figure 39: Sequence of Operation

I. Sequence of Operation. See Figure 39. If boiler fails

to operate properly, see Troubleshooting Tree in Section
IX: Service.

J. Check pilot burner ame. See Figure 41. Flame

should be steady, medium hard blue enveloping 3/8 to
½ inch of sensing probe.

K. Check main burner ame. See Figures 40. Flame

should have clearly dened inner cone with no yellow

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 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).

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. Rell boiler.

69

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

13 to determine gas ow rate in Cubic Feet per

Hour.

WARNING

Failure to properly adjust gas input rate will result

in over ring or under ring of the appliance.

Improper and unsafe boiler operation may result.

4. Determine Input Rate. Multiply gas ow rate by gas

heating value.

5. Compare measured input rate to input rate stated on
rating plate.

a. Boiler must not be over red. Reduce input rate

by decreasing manifold pressure. Do not reduce

more than 0.3 inch w.c. If boiler is still overred,

contact your Burnham distributor or Regional

Ofce for replacement Gas Orice.

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 orices. Drill one (1) drill size

larger (drill size is stamped on orice, or see

Section X: Repair Parts).

iii. Reinstall gas orices and main burners.

Measure input rate.

6. Recheck Main Burner Flame.

7. Return other gas-red appliances to previous

conditions of use.

Q. Review User’s Information Manual and system

operation with owner or operator.

TABLE 13: GAS FLOW RATE IN CUBIC FEET
PER HOUR

Seconds

for One

Revolution

30 60 120 240
32 56 113 225

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

Size of Gas Meter Dial

One-Half

Cu. Ft.

One

Cu. Ft.

Two

Cu. Ft.

70

IX. Service

DANGER

This boiler uses ammable gas, high voltage electricity, moving parts, and very hot water under high

pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool
before attempting any disassembly or 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.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians.
If any controls are replaced, they must be replaced with identical models.

Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.

If any electrical wires are disconnected during service, clearly label the wires and assure that the wires
are reconnected properly.

Never jump out or bypass any safety or operating control or component of this boiler.
Read, understand and follow all the instructions and warnings contained in ALL of the component

instruction manuals.
Assure that all safety and operating controls and components are operating properly before placing

the boiler back in service.

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 36.

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

eld. 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,

ttings, 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.

4. Pipe must be supported at minimum ve (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 ow freely. To Clean:
a. Disconnect drain tube from drain tting.

b. Flush drain tube with water. Fill trap with water.

c. Securely fasten drain tube to drain tting,

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 44.
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.

71

d. Remove wires to Flame Roll-out Switch.
e. Remove air diffuser screen.
f. Remove Burner Access Panel.
g. Mark location of Main Burner with Pilot Bracket

on gas manifold.

h. Hold Main Burner on throat. Lift front of

burners to clear orice. Burner which holds pilot

can be removed by lifting the burner adjacent to

its right rst.

2. Disconnect Vent Connector and Vent Pipe from
Blower Outlet

3. Remove Jacket Top Panel.

4. Disconnect the Black and Gary Silicone Tubing
from the Canopy.

5. Disconnect Wiring Harness from Blower Motor.

6. Remove Canopy/Blower Assembly.
a. Loosen the (4) screws from Canopy.

7. Remove Flue Gas Bafes. Inspect Flue Gas Bafes

for deterioration.

8. Inspect ue passages. Clean with ue brush. See

Figure 44.

9. Inspect heating surface in combustion chamber.
Clean with straight handle wire brush.

10. Install Flue Gas Bafes.

11. Replace Canopy/Blower Assembly.

12. Connect Silicone Tubing between Pressure Fittings
on Canopy Assembly and Pressure Switch. Route
through bushings in Vestibule Panel . See Figure

42.

Figure 42: Silicone Tubing Assembly

13. Install Jacket Top Rear Panel.

14. Connect Vent System. See Figure 43.

15. Connect Blower Motor Wiring Harness.

Figure 43: Blower Vent Connector Assembly

TABLE 14: PILOT BURNER LOCATION

Boiler Model Main Burner with Pilot Bracket Pilot Burner Located Between Main Burners *

SCG-3 2 2 & 3
SCG-4 3 3 & 4
SCG-5 4 4 & 5
SCG-6 5 5 & 6
SCG-7 6 6 & 7
SCG-8 7 7 & 8

SCG-9 8 8 & 9

* Main burners numbered left to right as viewed from front of boiler.

72

Figure 44: Flue and Burner Cleanout, 1” Burner

73

E. Main Burners and Firebox.

1. Vacuum rebox. Exercise care - do not damage base

insulation.

2. Clean main burners. Brush top of burners with soft
bristle brush. See Figure 44. Vacuum to remove any
dirt and lint.

3. Vacuum tip of pilot burner.

4. Check gas orices 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 14.

b. Main burners must be properly secured in burner

tray slot at rear of rebox and over gas orice.

See Figure 44.

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.

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.

4. Stop boiler, remove manometer and reconnect hoses
to differential pressure switch. See Figures 42 and

45.

G. Procedure for Measuring Differential Pressure (See

Figure 45).

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 15 for minimum
readings.

TABLE 15: DIFFERENTIAL PRESSURE SWITCH SETTINGS

Minimum Differential Pressure

Boiler Model

Sea Level to 4,999 Ft. 5,000 - 10,000 Ft. Elevation

SCG-3 1.32” w.c. .80” w.c.
SCG-4 1.17” w.c. .65” w.c.

SCG-5 1.17” w.c. .65” w.c.
SCG-6 .88” w.c. .35” w.c.

Figure 45: Differential Pressure Measurement

74

SCG-7 .80” w.c. .30” w.c.
SCG-8 .88” w.c. .35” w.c.

SCG-9 .88” w.c. .35” w.c.

THIS PAGE LEFT INTENTIONALLY BLANK

75

767778

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 [phone] or Fax [phone].

Key

No.

Description

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

[Quantity] Part Number

1. CASTING ASSEMBLY

1 Section Assembly 61707031 61707041 61707051 61707061 61707071 61707081 61707091

1A Left End Section 71707001

1B Center Section

1C Right End Section 71707002

1D Slip Nipple, #3

1E Flue Gas Bafe

1F Tie Rod, ¼” -20

1G Hex Nut, ¼” -20 (4) 80860407

(1)

71707003

(4)

806600009

(2)

71107002

(2)

100109-01

(2)

71707003

(6)

806600009

(3)

71107002

(2)

100108-05

(3)

71707003

(8)

806600009

(4)

71107002

(2)

100108-07

(4)

71707003

(10)

806600009

(5)

71107002

(2)

100108-13

(5)

71707003

(12)

806600009

(6)

71107002

(2)

100108-14

(6)

71707003

(14)

806600009

(7)

71107002

(2)

100108-15

(7)

71707003

(16)

806600009

(8)

71107002

(2)

100108-16

79

80

Key

No.

Description

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

[Quantity] Part Number

2. BASE ASSEMBLY

2A Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091

2B Base Tray 71807032 71807042 71807052 71807062 71807072 71807082 71807092

2C Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091

2D Base Front Panel 71807035 71807045 71807055 71807065 71807075 71807085 71807095

2E Burner 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 Insulation 72007031 72007041 72007051 72007061 72007071 72007081 72007091

2K Base Front Insulation 72007032 72007042 72007052 72007062 72007072 72007082 72007092

2L Base Leg Assembly (4) 6186001

2M Self Tapping Screw, 1/4” -20 x 1/2” (18) 80860700

2N Flame Roll-out Switch 80160044

2P Sheet Metal Screw, #8 x 3/4” 80860030

2Q Self Tapping Screw, 10 -32 x 3/8” (5) 80860705 (6) 80860705 (7) 80860705

2R Self Tapping Screw Hex Cap, 5/16 -18 x 1-1/4” (4) 80860717

81

82

Key

No.

Description

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

[Quantity] Part Number

2. BASE ENCLOSURE ASSEMBLY

3A Air Box Assembly 61807032 61807042 61807052 61807062 61807072 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 Gasket Cover Plate 7096002

3E Pilot Tube Gasket 8206038

3F Window Plug 102202-01

3J Sheet Metal Screws #8 x 1/2” (6) 80860000

3K Self Tapping Screw, 10-32 x 3/8” (18) 80860705 (22) 80860705

83

84

Key

No.

Description

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

[Quantity] Part Number

4. FAN/CANOPY ASSEMBLY

Canopy Assembly - Sea Level 61107031 61107041 61107051 61107061 61107071 61107081 61107091

4A

Canopy Assembly - High Altitude 61107032 61107042 61107052 61107062 61107072 61107082 61107092

4B Cerafelt 9206005

4C U-Clip (4) 80861512

4D Sheet Metal Screw, #10 x 1” (4) 808600141

4E Fan Gasket 8206085

4F Fan 81161512

4G Lock Washer, #10 (4) 80860636

4H Machine Screw, #10-24 x 2½” (4) 808608982

85

86

Key

No.

Description

5. BURNER ASSEMBLIES

[Quantity] Part Number

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

Gas Valve (Natural Gas),
Honeywell VR8204P1171

Gas Valve (Natural Gas),
Honeywell VR8304P4496

5A

Gas Valve (LP Gas),
Honeywell VR8204C3015

Gas Valve (LP Gas),
Honeywell VR8304P4280

Nipple, ½” NPT x Close 806600040 N/A

5B

Nipple, ¾” NPT x Close N/A 806600022
Union, ½” NPT 806604023 N/A

5C

Union, ¾” NPT N/A 806604001
½” Gas Manifold 82207031 82207041 82207051 82207061 --- --- ---

5D

¾” Gas Manifold --- --- --- --- 82207071 82207081 82207191

Burner Orices - Natural Gas #47

5E

Burner Orices - LP Gas 1.20 mm

Pilot Assembly - Natural Gas 8236163

5F

Pilot Assembly - LP Gas 8236164

5G Pilot Burner 100147-01

5H Main Burner

5J Pilot Tubing 8236122
5K Self Tapping Screw, ¼ - 20 x ½” (6) 80860700

(4)

822710

(4)

822792

(3)

100146-01

81660282 N/A

N/A 81660283

81660146 N/A

N/A 81660160

(6)

822710

(6)

822792

(5)

100146-01

(8)

822710

(8)

822792

(7)

100146-01

(10)

822710

(10)

822792

(9)

100146-01

(12)

822710

(12)

822792

(11)

100146-01

(14)

822710

(14)

822792

(13)

100146-01

(16)

822710

(16)

822792

(15)

100146-01

87

88

Key

No.

Description

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

[Quantity] Part Number

6. CONTROL PANEL ASSEMBLY

6A Limit, Honeywell L4080D 100189-01

6B Transformer/Relay, Honeywell R8285D 80160155U

6C Ignition Module, Honeywell S8670E3003 100959-01

6D Blower Relay, Honeywell R8222U1006 80160096U

Differential Pressure Switch

Sea Level 0’ - 4999’

6E

High Altitude - 5000’ - 10,000’ 80160759 80160763 80160764 80160765 80160764

6F Junction Box 8136259

80160762 80160761 80160760 80160759 80160760

89

90

Key

No.

Description

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

[Quantity] Part Number

7. JACKET PARTS

7A Jacket Left Side Panel 60407002
7B Jacket Right Side Panel 60407001
7C Rear Panel 60407033 60407043 60407053 60407063 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 Door 101354-03 101354-04 101354-05 101354-06 101354-07 101354-08 101354-09

7G Air Intake Collar Assembly 60407003 60407004 60407005

7H Handle 8056184

7J Door Clip (2) 7041921

7K Bushing 8136048

7L Burnham Logo 81460099

91

Key

No.

Description

[Quantity] Part Number

SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9

8. MISCELLANEOUS 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 8110701 8110702
8G Air Intake Terminal 6116045 6116044 6116063
8H Vent Connector 8110703 8110704

92

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. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts 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 airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.

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.

93

SERVICE RECORD

DATE SERVICE PERFORMED

94

SERVICE RECORD

DATE SERVICE PERFORMED

95

79

water boiler for its intended purposes and its maintenance
accordance with U. S. Boiler Co., Inc. recommendations and
hydronics industry standards. These warranties will be inapplicable if
the residential grade water boiler is used or operated over its rated
capacity, is subjected to unauthorized modification, or is damaged as
a result of 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.

Limited Warranty

FOR RESIDENTIAL CAST IRON WATER BOILERS

03/03

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:

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.

4. Proper Use and Maintenance: The warranties extended by U.S.

Boiler Co., Inc. conditioned upon the use of the residential grade

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