Burnham SCG 1100-H4 User Manual

As an ENERGY STAR

DNAGNITAREPO,NOITALLATSNI

ROFSNOITCURTSNIECIVRES

™GCS

RELIOBDERIF-SAG

nonoitamrofnignikeesnehW.rotcartnocgnitaehruoyllac,reliobotsriaperroecivresroF

.lebaLgnitaRnonwohssarebmuNlaireSdnarebmuNledoMrelioBedivorp,reliob

rebmuNledoMrelioB

GCS

rebmuNlaireSrelioB etaDnoitallatsnI

rotcartnoCgnitaeH rebmuNenohP

sserddA

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.

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.

Table of Contents

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

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

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

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

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

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

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

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

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

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

Figure 1: Minimum Clearances to Combustibles

Figure 2: Dimensions

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.

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.

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

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)

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

Equal to

Installed Length

(1.06 TO 1.64)

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

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.

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

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.

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

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

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

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.

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.

Figure 7: Attic OffsetFigure 6: Vertical Vent Installation

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-

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

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.

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

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.

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.

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

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

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

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.

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.

+ 67 hidden pages

Burnham SCG 1100-H4 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual