Burnham SCG User Manual

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

SCG™

GAS - FIRED BOILER

As an ENERGY STAR^®Partner, Burnham Hydronics has determined that the SCG meets the ENERGY

STAR^®guidelines for energy efﬁciency established by the United States Environmental Protection Agency (EPA).

For service or repairs to boiler, call your heating contractor. When seeking information on

boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

Boiler Serial Number

Installation Date

SCG _ _ _ _ - _ _ _

_ _ _ _ _ _ _ _

Heating Contractor

Phone Number

Address

8140705R3-1/07

Price - $5.00

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 efficiency.

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 fittings

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 instructions, 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 flammable

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

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

VII. Modular Installation .................... 62

VIII. System Start-up ............................ 64

IX. Service .......................................... 68

X. Repair Parts.................................. 74

II. Unpack Boiler ................................ 7

III. Venting/Air Intake Piping .............. 8

IV. Water Piping and Trim ................. 45

V. Gas Piping.................................... 50

Figure 1: Minimum Clearances to Combustibles

I. Pre-Installation

WARNING

F. Provide combustion and ventilation air in accordance

with applicable provisions of local building codes,

or: USA - National Fuel Gas Code, NFPA 54/ANSI

Z223.1, Air for Combustion and Ventilation;

Canada - Natural Gas Installation Code, CAN/

CGA-B149.1, or Propane Installation Code, CAN/

CGA-B149.2, Venting Systems and Air Supply for

Appliances.

If you do not follow these instructions

exactly, a fire or explosion may result

causing property damage or personal

injury.

DANGER

WARNING

Do not install boiler where gasoline or other

flammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, cleaners,

chemicals, sprays, paint removers, fabric

softeners, etc.) are used or stored.

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.

NOTICE

1. Determine volume of space (boiler room). Rooms

communicating directly with space (through

openings not furnished with doors) are considered

part of space.

Due to the low water content of the boiler,

mis-sizing 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.

Volume [ft³] = Length [ft] x Width [ft] x Height [ft]

2. Determine Total Input of all appliances in space.

Round result to nearest 1,000 Btu per hour (Btuh).

3. Determine type of space. Divide Volume by Total

Input.

a. If result is greater than or equal to 50 ft³ per

1,000 Btuh, space is considered an unconﬁned

space.

A. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such

requirements, installation must conform to the National

Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/

CGA B149 Installation Codes.

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

is considered a conﬁned space.

4. Determine building type. A building of unusually

tight construction has the following characteristics:

a. Walls and ceiling exposed to outside atmosphere

have a continuous water vapor retarder with a

rating of 1 perm or less with openings gasketed

and sealed, and;

B. Appliance is design certiﬁed for installation on

combustible ﬂooring. Do not install boiler on

carpeting.

b. Weather-stripping has been added on openable

windows and doors, and;

C. Provide clearance between boiler jacket and

combustible material in accordance with local ﬁre

ordinance. Refer to Figure 1 for minimum listed

clearance from combustible material. Recommended

service clearance is 24 inches from left side, right

side and front. Service clearances may be reduced to

minimum clearances to combustible materials.

c. Caulking or sealants applied in joints around

window and door frames, between sill plates and

ﬂoors, between wall-ceiling joints, between wall

panels, at plumbing and electrical penetrations,

and at other openings.

5. For boiler located in an unconﬁned space in a

building of other than unusually tight construction,

adequate combustion and ventilation air is normally

provided by fresh air inﬁltration through cracks

around windows and doors.

D. Install on level ﬂoor. For basement installation provide

solid base such as concrete, if ﬂoor is not level or if

water may be encountered on ﬂoor around boiler. Floor

must be able to support weight of boiler, water and all

additional system components.

E. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation

and service (circulator replacement, condensate trap,

control replacement, etc.).

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.

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 this

manual.

Alternate method for boiler located within

conﬁned space. Use indoor air if two permanent

openings communicate directly with additional

space(s) of sufﬁcient volume such that combined

volume of all spaces meet criteria for unconﬁned

space. Size each opening for minimum free area

of one (1) square inch per 1,000 Btu per hour

input of all equipment in spaces, but not less than

100 square inches.

6. For boiler located within unconﬁned space in building

of unusually tight construction or within conﬁned

space, provide outdoor air through two permanent

openings which communicate directly or by duct

with the outdoors or spaces (crawl or attic) freely

communicating with the outdoors. Locate one opening

within twelve (12) inches of top of space. Locate

remaining opening within twelve (12) inches of bottom

of space. Minimum dimension of air opening is three

(3) inches. Size each opening per following:

7. Combustion Air/Ventilation Duct Louvers and

Grilles. Equip outside openings with louvers to

prevent entrance of rain and snow, and screens to

prevent entrance of insects and rodents. Louvers and

grilles must be ﬁxed in open position or interlocked

with equipment to open automatically before burner

operation. Screens must not be smaller than ¼ inch

mesh.

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.

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.

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.

CAUTION

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

environment where saw dust, loose insulation fibers, dry wall dust, etc. are present. If boiler is

operated under these conditions, the burner interior and ports must be cleaned and inspected daily

to insure proper operation.

II. Unpack Boiler

WARNING

CAUTION

Installation of this boiler should be

undertaken only by trained and skilled

personnel from a qualified service agency.

Do not drop boiler. Do not bump boiler

jacket against floor.

A. Move boiler to approximate installed position.

E. Tilt the boiler to its front side or back side and slide a

wooden slat under the three raised feet.

B. Remove all crate fasteners.

F. Tilt the boiler in the opposite direction and slide

C. Lift and remove outside container. Save two of the

wooden slats from the container sleeve for use in Steps

E and F.

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.

D. Remove all boiler hold-down fasteners.

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 flammable vapors or liquids, or sources of

hydrocarbons (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

Installation

Additional

Part

Number

Drawing and

Specification

(See Section)

Option

Description

Vent Kit

Required

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.

1. Separate

Horizontal

See

Table 2

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.

2. Separate

Vertical

See

Table 2

Direct Vent (sealed combustion) with the vent pipe

3. Combination and air intake pipe joining at a common terminal

3 - 6 Section

(61106012)

Yes

Horizontal

and terminating horizontally (through a sidewall up

to 15" thick) with only one penetration.

Direct Vent (sealed combustion) with the vent pipe

4. Combination and air intake pipe joining at a common terminal

3 - 4 Section

(100222-01)

5 - 6 Section

(100223-01)

Yes

Vertical

and terminating vertically (through the roof) with

only one penetration.

Power Vent - Air used for combustion is provided

from within the building.

5. Indoor Air

See Table 2

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.

6. Optional

Separate

See Table 2

Horizontal

Table 2: Vent System Components Included with Boiler

Vent System Components

Part Number

8110701

Gasketed Vent Terminal 3"

Horizontal (SCG-3 thru SCG-7)

Gasketed Vent Terminal 4"

Horizontal (SCG-8 & SCG 9)

8110702

6116045

6116049

6116063

Disc Air Intake - 3"

(SCG-3 & SCG-4)

Disc Air Intake - 4"

(SCG-5 & SCG-6)

Air Intake - 5"

(SCG-7 thru SCG-9)

Table 3: Burnham Vent System and Air Intake System Components

Vent System

Component

Part

Number

Equivalent

Feet of Pipe

3" Dia. Pipe x 1 Ft

8116296U

100176-01

8116298U

100177-01

8116300U

100178-01

8116319U

4" Dia. Pipe x 1 Ft

3" Dia. Pipe x 3 Ft

4" Dia. Pipe x 3 Ft

3" Dia. Pipe x 5 Ft

4" Dia. Pipe x 5 Ft

3" Dia. Pipe x Adjustable

Intake System

Components

(Parts by Others)

Equivalent

Feet of Pipe *

3", 4", or 5" ID Pipe x 1 Ft

3", 4", or 5" ID Pipe x 2 Ft

3", 4", or 5" ID Pipe x 4 Ft

3", 4", or 5" ID Pipe x 5 Ft

3", or 4" 90° Elbow

**Equal to

Installed Length

(1.06 to 1.64)

4" Dia. Pipe x Adjustable

3" Dia. 90° Elbow

100179-01

8116294U

100180-01

8116292U

100181-01

8166302U

100182-01

8116304U

100183-01

8116116

4" Dia. 90° Elbow

3", or 4" 45° Elbow

3" Dia. 45° Elbow

4" Dia. 45° Elbow

5" 90° Elbow

3" Dia. Horizontal Drain Tee

4" Dia. Horizontal Drain Tee

3" Dia. Vertical Drain Tee

4" Dia. Vertical Drain Tee

3" Single Wall Thimble

4" Single Wall Thimble

3" Double Wall Thimble

4" Double Wall Thimble

5" 45° Elbow

7½

---

* Equivalent Feet of Pipe Based on

Standard 4" Smoke Pipe Design

100184-01

8116115

100185-01

Table 4: Vent/Air Intake Length

3" Air Intake Pipe 4" Air IntakePipe 5" Air IntakePipe

(Equiv. Ft.) (Equiv. Ft.) (Equiv. Ft.)

3" Vent Pipe

(Equiv. Ft.)

4" Vent Pipe

(Equiv. Ft.)

Model

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

50 ---- ---- ---- ----

Min.

Max.

Min.

----

Max.

----

SCG-3 & SCG-4

SCG-5 & SCG-6

SCG-7

----

SCG-8 & SCG-9

----

A. Vent Guidelines Due to Removal of an Existing

Boiler

B. General Guidelines

1. Vent system installation must be in accordance

with National Fuel Gas Code, NFPA 54/ANSI

Z221.3 or applicable provisions of local building

codes. Contact local building or ﬁre ofﬁcials about

restrictions and installation inspection in your area.

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:

2. The SCG is designed to be installed as either

a Direct Vent boiler or Power Vent boiler. In

the Direct Vent conﬁguration all of the air for

combustion is supplied directly to the burner

enclosure from outdoors and ﬂue gases are vented

directly outdoors (through wall or roof). In the

Power Vent conﬁguration, room air provides air

for combustion and ventilation. Flue gases are still

vented directly outdoors (through wall or roof).

Note: Venting requirements change if indoor air is

used.

1. Seal any unused openings in the common venting

system.

2. Visually inspect the venting system for proper

size and horizontal pitch and determine there is no

blockage or restriction, leakage, corrosion, and other

deﬁciencies which could cause an unsafe condition.

3. Refer to the appropriate drawings in this section of

this manual to determine the proper conﬁguration of

venting system. See Table 1.

3. Insofar as is practical, close all building doors and

windows and all doors between the space in which

the appliances remaining connected to the common

venting system are located and other spaces of the

building. Turn on clothes dryers and any appliance

not connected to the common venting system.

Turn on any exhaust fans, such as range-hoods and

bathroom exhausts, so they will operate at maximum

speed. Do not operate a summer exhaust fan. Close

ﬁreplace dampers.

4. This appliance requires a Special Gas Vent. The

product is designed to use Burnham supplied

AL 29-4C^®Stainless Steel vent system components.

The following manufacturers offer similar

AL 29-4C^®components and are approved for use

with this product. Heat-Fab Inc. - Saf-T-Vent, Flex-L

International Inc. - Star-34, Z-Flex U. S., Inc. -

Z-Vent, and Protech Systems , Inc.- FasNSeal™ or

equivalent. The use of these alternate manufacturer’s

venting systems will require adapters to connect

to the Burnham supplied vent connector and vent

terminal. These adapters are not supplied with this

unit and should be obtained from the supplier of

the alternate manufacturer’s venting system. See

Table 3 for complete list of Burnham Vent System

Components.

4. Place in operation the appliance being inspected.

Follow the Lighting (or Operating) Instructions.

Adjust thermostat so appliance will operate

continuously.

5. Test for spillage at the draft hood relief opening

after ﬁve (5) minutes of main burner operation. Use

the ﬂame of a match or candle, or smoke from a

cigarette, cigar or pipe.

5. Horizontal vent pipe must maintain a minimum ¼

inch per foot slope down towards boiler.

6. After it has been determined that each appliance

remaining connected to the common venting system

properly vents when tested as outlined above, return

doors, windows, exhaust fans, ﬁreplace dampers and

any other gas burning appliance to their previous

conditions of use.

6. Use noncombustible ¾ inch pipe strap to support

horizontal runs and maintain vent location and

slope while preventing sags in pipe. Do not restrict

thermal expansion or movement of vent system.

Maximum support spacing is ﬁve (5) feet. Do not

penetrate any part of the vent system with fasteners.

7. Any improper operation of the common venting

system should be corrected so the installation

conforms with the National Fuel Gas Code, NFPA

54/ANSI Z223.1. When resizing any portion of the

common venting system, the common venting

system should be resized to approach the minimum

size as determined using the appropriate tables in

Part II in the National Fuel Gas Code, NFPA 54/

ANSI Z223.1.

7. Vent length restrictions are based on equivalent

length of vent/air pipe (total length of straight

pipe plus equivalent length of ﬁttings). Maximum

vent/air lengths are listed in Table 4. Do not exceed

maximum vent/air intake lengths. Table 3 lists

equivalent lengths for ﬁttings. Do not include vent/

air terminals in equivalent feet calculations.

8. Provide and maintain vent pipe minimum clearances

to combustible materials. Vent pipe minimum

clearance to combustible material is four (4) inches

when vent is installed in a fully enclosed (chase)

application or three (3) inches when vent is installed

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.

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.

12. Once a vent pipe manufacturer and system is chosen

never mix and match vent systems.

9. Do not install venting system components on

the exterior of the building except as speciﬁcally

required by these instructions. The vent termination

location is restricted as follows:

13. If a non-standard length pipe is required:

Gasketed Vent System: The use of the adjustable

length pipe (P/N 8116319U) is recommended to

complete a non-standard pipe length. This pipe

requires a minimum installed length of 12¾ inch

and can adjust across a 7 inch gap up to a maximum

of 19¾ inch long. (Note for the adjustable pipe

the installed length should be measured from the

centerline of the bead on the male end of the ﬁrst

pipe to the end of the female pipe excluding the

locking band of the second pipe with a single

gasket.) Only in the event the adjustable length pipe

is not sufﬁcient a standard length pipe may be cut

using the procedure outlined below for the Gasket-

Less Vent System.

a. Minimum twelve (12) inches above grade plus

normally expected snow accumulation level, or

seven (7) feet above grade if located adjacent

to public walkway. Do not install over public

walkway where local experience indicates

appliance ﬂue gas vapor or condensate creates a

nuisance or hazard.

b. Minimum three (3) feet above any forced air

inlet located within ten (10) feet.

c. Direct Vent - Minimum one (1) foot below, one

(1) foot horizontally from, or one (1) foot above

any door, window, or gravity air inlet.

Power Vent - Minimum four (4) feet below, four

(4) feet horizontally from, or four (4) feet above

any door, window, or gravity air inlet.

WARNING

Never exceed maximum installed length of

19¾ inches for adjustable length pipe.

Risk of flue gas leakage is possible.

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.

NOTICE

e. Minimum twelve (12) inches from overhang or

corner of building.

Cut must be square with pipe and filed or

sanded smooth before joining. Carefully

ensure roundness of cut pipe by hand with

gloves before installing. Seal joint with RTV

specified in this manual.

10. Enclose vent passing through occupied or

unoccupied spaces above the boiler with material

having a ﬁre resistance rating of at least equal to the

rating of the adjoining ﬂoor or ceiling. Maintain

minimum clearances to combustible materials. See

Figure 1.

C. Install Vent Pipe, Burnham Gasketed Vent System.

1. Procedure for Joining Burnham Gasketed Vent Pipe

and Fittings. See Figure 3.

Note: For one or two family dwellings, ﬁre

resistance rating requirement may not need to be

met, but is recommended.

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.

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.

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 factory-

installed gasket is not dislodged or cut.

9. Do not exceed air intake length. See Table 4.

10. Use single wall metal or PVC pipe.

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!

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.

d. Once the installation is complete, operate

appliance and inspect all joints to ensure that ﬂue

gases and/or liquid condensate will not escape.

11. Air intake termination must be located:

Horizontal - At least twelve (12) inches above

grade plus the expected snow accumulation.

D. Separate Horizontal Venting System. See Figures 4,

12. Start at collar on burner enclosure (inside boiler

jacket) and work towards the air intake terminal.

5A and 5B.

Vent Piping –

13. Maintain minimum of ¼ inch per foot slope on

horizontal runs. Slope towards air inlet terminal

when possible. If not, slope towards boiler.

1. This boiler is supplied with components as standard

equipment for installation of the separate horizontal

venting system.

14. The air intake pipe must be adequately supported

with straps or supports no less than ﬁve (5) feet

apart on horizontal runs. The complete air intake

piping system must be rigid and able to withstand

minor impacts without collapse.

2. Do not exceed maximum vent/air intake lengths.

Refer to Table 4.

3. Recommended horizontal installation consists of

vent being sloped down ¼ inch per foot away from

boiler. See Figure 4.

15. Inlet air pipe penetration:

4. Use appropriate designed thimbles when passing

through combustible walls (thimble use optional for

noncombustible walls). Insert thimble through wall

from outside. Secure outside ﬂange to wall with

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

sealant material. Install inside ﬂange to inside wall,

secure with nails or screws, and seal with sealant

material.

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 self-

adhesive aluminum tape.

17. Install Air Intake Terminal:

Horizontal - Remove four (4) screws from cover

plate and remove cover plate from terminal. Insert

intake piping into intake terminal collar. Secure

terminal to intake piping and seal joint with silicone

caulk or self-adhesive aluminum tape. Apply

continuous bead of silicone caulk around the back

of the intake terminal, approximately ¼ inch from

its edge. Push inlet terminal inward until terminal’s

back ﬂange is against the wall surface. Secure the

terminal with noncorrosive fasteners (stainless steel,

brass or aluminum) to the wall. Reinstall the cover

plate with four (4) screws. Apply a bead of silicone

caulk to perimeter of intake terminal’s back ﬂange

to provide a weathertight seal.

5. For noncombustible wall application when thimble

is not used, size opening such that bell with locking

band attached cannot pass through.

6. Join vent terminal to vent pipe. See Figures 5A and

5B.

7. Insert vent pipe through thimble/opening from

outside and join to vent system. Apply sealant

between vent pipe and opening/thimble to provide

weathertight seal.

Air Intake piping - See Figures 4, 5A and 5B.

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

NOTICE

Roof penetrations require the use of roof

flashing and storm collar - not supplied with

boiler.

Vertical Venting –

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.

1. Do not exceed maximum vent lengths. Refer to

Table 4.

2. Installation of a vertical vent tee 8116304U is

required on all vertical vent applications. See

Figures 6 and 7. Attach vertical vent drain tee

directly to elbow or horizontal pipe from an elbow

immediately after vent connector.

9. Use single wall metal pipe or PVC and ﬁttings

available at most heating distributors.

a. Air intake pipe diameter is based on boiler size.

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.

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.

4. Install ﬁre stops where vent passes through ﬂoors,

ceilings or framed walls. The ﬁre stop must close

the opening between the vent pipe and the structure.

10. Air intake termination must be located:

Vertical - At least twelve (12) inches above the roof

surface plus the expected snow accumulation.

5. Whenever possible, install vent straight through

the roof. Refer to Figure 7 if offset is necessary.

Maintain minimum clearance to combustible

materials.

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.

6. Install Vent Terminal.

13. The air intake pipe must be adequately supported

with straps or supports no less than ﬁve (5) feet

apart on horizontal runs. The complete air intake

piping system must be rigid and able to withstand

minor impacts without collapse.

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.

14. Inlet air pipe penetration:

Vertical - Size roof opening to allow easy insertion

of inlet piping and allow proper installation of

ﬂashing and storm collar.

NOTICE

a. Use appropriately designed vent ﬂashing

when passing through roofs. Follow ﬂashing

manufacturers’ instructions for installation

procedures. Flashing manufacturers are Air-

Jet, American Metal Products, Metal Fab, and

Simpson Dura-Vent.

Vertical venting requires the use of roof

flashing and a storm collar to prevent

moisture from entering the structure.

c. Install storm collar on vent pipe immediately

above ﬂashing. Apply Dow Corning Silastic 732

RTV Sealant between vent pipe and storm collar

to provide weathertight seal.

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.

d. Attach vent terminal.

Vertical Air Intake Piping –

7. Do not exceed maximum air intake length. Refer to

Table 4.

c. Vertical air intake requires ﬂashing and a storm

collar to prevent moisture from entering the

structure.

d. Install storm collar on air intake pipe

immediately above ﬂashing. Apply Dow

Corning Silastic 732 RTV Sealant between

air intake pipe and storm collar to provide

weathertight seal.

15. Seal all joints airtight, using silicone caulk or self-

adhesive 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.

e. All exposed air intake piping must be

constructed of corrosion resistant material such

as aluminum, stainless steel or PVC.

Figure 9: Vertical Air Intake Piping

F. Combination Horizontal Venting System –SCG-3 Through SCG-6 ONLY – See Figures 10 and 11.

1. Do not exceed maximum vent/air intake lengths.

Refer to Table 4.

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.

Vent Carton Part Number 61106012 (includes items below)

Description

Component Part Number

61106011

Air Box Sub-Assembly (6" square x 2' long)

Exterior Wall Cover (10" square)

71106016

4" x 3" Vent Pipe Reducer

8116239

Plate-Seal Exterior Cover (2)

71106017

#8 x ½" Stainless Steel Sheet Metal Screw (19)

#10 - 32 x ¼" Stainless Steel Machine Screw (8)

#10 - 32 x ½" Aluminum Spacer (4)

80860047

80860842

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 ﬂange is against wall, check

for level and mark the location of the four (4)

securing holes on the exterior wall. Remove air

box from wall.

3. Install Vent Piping. See Figure 10 and 11.

a. Start at vent connector on boiler and work

towards combination vent/air terminal.

b. Installation of a vertical vent tee 8116304U is

required on all vertical vent applications. See

Figures 12 and 13. Attach vertical vent drain

tee directly to elbow or horizontal pipe from an

elbow immediately after vent connector.

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

non-corrosive fasteners (stainless steel, brass, or

aluminum) to be used to secure the wall ﬂange to

the exterior wall. (Securing screws not supplied

with kit.)

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.

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

spacers to the outer ﬂanges of the exterior

wall ﬂange with four (4) number 10 - 32 x 1/4

inch stainless steel machine screws provided.

(See Figure 11.)

d. Use 3/4 inch pipe strap to support horizontal runs

and maintain vent location and slope. Maximum

support spacing is ﬁve (5) feet.

f. Apply a 1/4 inch thick continuous bead of

silicone caulk to perimeter of exterior wall

ﬂange’s back surface to provide a weathertight

seal.

e. Install vent piping to connect vent connector

on boiler and combination vent/air terminal.

Reference Section B - General Venting

Guidelines for proper procedure for joining pipe

and ﬁttings.

g. Reinstall air box sub-assembly into opening in

exterior wall and secure to wall.

f. Connect vent piping to combination vent/air

terminal. See Figure 10.

WARNING

4. Install Air Intake Piping. See Figures 10 and 11.

a. Do not exceed air intake length. See Table 4.

Non-corrosive fasteners must be used.

b. Use single wall metal pipe or PVC and ﬁttings

h. Apply a bead of silicone caulk to perimeter of

wall ﬂange, where the wall and ﬂange join. Use

a tool or your ﬁnger and apply pressure while

smoothing caulking to provide a weathertight

seal.

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.

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.)

d. Start at collar on burner enclosure (inside boiler

jacket) and work towards the combination vent/

air terminal.

j. Secure end panel to air box sub-assembly with

shipping screw and thirteen (13) number 8 sheet

metal screws provided.

e. Maintain minimum of 1/4 inch per foot slope on

horizontal runs. Slope down towards boiler.

k. From exterior of building, position 10 inch

square exterior wall cover over exterior wall

ﬂange. Insert 3 inch diameter vent pipe into

center opening in terminal cover. Align four

(4) holes on cover with 1/2 inch long threaded

spacers on wall ﬂange. Secure terminal cover

with four (4) number 10 - 32 x 1/4 inch stainless

steel machine screws provided.

f. The air intake pipe must be adequately supported

with straps or supports no less than ﬁve (5)

feet apart on horizontal runs. The complete air

intake piping system must be rigid and able to

withstand minor impacts without collapse.

g. Connect Air Intake Piping to Combination Vent/

Air Terminal. See Figure 10.

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.

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).

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).

h. Seal all joints airtight, using silicone caulk or

self-adhesive aluminum tape.

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.

Part Number

SCG-5 & SCG-6

Description

SCG-3 & SCG-4

100222-01

Vent Carton Part Number

Starter Tee

100223-01

100225-01

100224-01

Vent/Air Adaptor

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

ﬁnish.

the system in place. A continuous straight-line

pitch of at least ¼” (2°) to the foot on horizontal

runs must be maintained in order to properly rid

the system of the corrosive condensate.

5. General Installation Requirements:

•

Saf-T Vent SC vent sections, or other Saf-T

Vent products, must be used throughout the

entire length of the system. Alternatives such

as galvanized pipe, PVC, nonmetallic pipe,

prefabricated chimney, ﬁeld-fabricated vents

or Type B vent sections must not be used. Do

not mix pipes, ﬁttings, or joining methods from

different manufacturers.

2. As a Special Gas Vent system: Saf-T Vent is

approved for use on ANSI Category I, II, III, and

IV Gas-Burning Appliances and certain Direct Vent

Appliances. Saf-T Vent SC is appropriate for use on

appliances that specify an AL29-4C venting system.

3. As a Sealed Combustion system: The unique

concentric design of Saf-T Vent SC also allows it

to function as a pipe-in-a-pipe vent. Products of

combustion are exhausted out through the inner wall

while combustion air is drawn in through the outer

wall. An appliance can be direct-vented with only

a single penetration through the building structure.

This application must be approved by the

Appliance Manufacturer.

•

More than one appliance may not be

interconnected to any part of the venting system.

Any penetrations of ceilings, ﬂoors or walls must

be properly ﬁre-stopped.

Whenever gas-burning equipment is installed in

the same space where halogenated substances

may exist (refrigerants, solvents, bleaches,

salts, etc.), clean outside air must be utilized for

combustion.

Note: Saf-T Vent SC includes an integral seal and

does not require RTV sealant. However, sealant

may be necessary when connecting Saf-T Vent SC

components directly to certain appliance ﬂue collars

and to the gasket-less Saf-T Vent GC and Saf-T Vent

CI vent systems.

•

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.

For applications up to 550°F/288°C, approved

sealants include GE RTV 106 and Dow Corning

736.

Combustible Material is any material made of

or surfaced with wood, compressed paper, plant

ﬁbers, or other materials that are capable of

being ignited or burned. Such material shall be

considered combustible even though it is ﬂame-

proofed, ﬁre-retardant, or plastered. (Source:

NPFPA54/ANSI Z223.1-1999.)

For applications up to 300°F/149°C, approved

sealants include GE RTV 106 and Dow Corning

732.

4. Pre-Installation Considerations:

•

Proper planning prior to installation is essential

as to avoid possible contact with concealed

plumbing or electrical wiring inside walls,

ﬂoors or ceilings as well as maintaining proper

clearances. Be sure to plan a sufﬁcient number

of supports for the entire system that will

•

Non-Combustible Material is any material that

is not capable of being ignited and burned, such

material consisting entirely of, or a combination

of, steel, iron, brick, tile, concrete, slate,

asbestos, glass and plaster. (Source: NPFPA54/

ANSI Z223.1-1999.)

maintain the required straight-line pitch and hold

Clearances to Combustibles:

Clearance to

Maximum Flue

Diameter Combustible

Gas Temp. (°F)

Orientation

Enclosure

Material

Vertical,

No Offsets

550

Fully enclosed by combustible

material on all sides

330

Horizontal,

Vertical with

Offsets

400

3" - 4"

Unenclosed, at least 1 side open,

combustible material on a

maximum of 3 sides

550

Any

Noncombustible material

6. Vertical Installation Requirements:

•

For a venting system that extends through

any zone above that on which the connected

appliance is located (except for one and two

family dwellings), the vent system shall be

enclosed with an enclosure having a ﬁre

resistance rating equal to or greater than that of

the ﬂoor or roof assemblies through which it

passes.

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.

•

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.

d. The total continuous distance of the vent system

from the appliance ﬂue collar to the termination

shall not exceed that speciﬁed in the appliance

manufacturer’s installation instructions.

e. In cold climates do not install a condensate drain

on the exterior of the building. Doing so may

result in dangerous icy conditions on surfaces

near the drain and may cause damage to the vent

system and/or the building exterior.

f. Install supports every 10 feet vertically along the

vent pipe route. Vertical supports are required

after every transition to vertical and are required

after every offset elbow. When the vent is free

standing and penetrates a roof/ceiling another

means of support must be used at a second

location. Refer to the Vertical Supports section

in this manual.

7. Joint Assembly Instructions:

a. Before joining the sections or ﬁttings together, use an alcohol pad to wipe the joint area of both ends of the inner

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

female ends (ends with the red seal) pointing away from the appliance. (Unless speciﬁed differently by the appliance

manufacturer.)

b. Insert the male end of the inner pipe into the female end of the previous section. In extremely dry conditions it may be

helpful to moisten the seal with clean water prior to assembly. Push ﬁrmly until the outer jacket has made contact with

the snap ring located inside the female end of the previous section. When fully assembled the outer female end will

overlap the male end 1”.

c. Use the three (3) self-tapping screws provided to connect the outer vents. No pre-drilling is required.

CAUTION

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.

8. Straight Sections Cut To Length:

e. Add 3” to the distance measured previously for the

cut length of the inner vent pipe. Mark a cut line on

the inner vent on the male end (the end without the

red seal).

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).

The inner pipe is always cut 1” longer than the

outer pipe.

f. WEAR GLOVES, as cut ends are very sharp. Cut

the pipes with an abrasive cutoff saw, plasma cutter,

or compound snips. If using snips, start the cut at

the male end and follow a spiral path around the pipe

until the cutoff mark is reached. File off any burrs

or rough edges that develop in the cutting process

and clean off any dust or grit. If the cutting process

distorts the roundness of the pipes, carefully use your

thumbs to re-round the ends.

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.

g. Reassemble the inner vent into the outer jacket and

reinstall the snap ring into the groove. Push the

inner vent into the outer jacket until the triangle on

the inner vent is seated ﬁrmly against the bead on

outer jacket. Start one end of the snap ring into the

groove of the outer pipe. Slowly turn and feet the

snap ring into the groove in a spiral motion, and

continue around the pipe until the snap ring is fully

inserted. Ensure that the triangle on the inner vent is

all the way down against the bead of the outer jacket

by pushing in ﬁrmly. Also ensure that the snap ring

is completely in the groove all the way around outer

jacket.

d. Add 2” to the distance measured previously for the

cut length of the outer jacket. Mark a cut line on the

outer jacket on the male end (the end without holes in

it).

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

around the section, assuring a square cut.

9. Air Intake Connections for Direct Vent and Sealed

Combustion Appliances*:

The Air Intake Tee may be used on approved direct vent

and sealed combustion appliances that have separate (non-

concentric) air intake and ﬂue exhaust collars. The male end

of the tee connects to EZ Seal appliance adapters and the tee

takeoff/snout connects to the appliance air intake.

•

Insert the male end of the Air Intake Tee into the female

end of the EZ Seal vent section or appliance adapter and

complete the ring and tab connection.

Insert the male end of the next SC section into the female

end of the Air Intake Tee and secure as described elsewhere

in this manual.

Connect the tee takeoff to the appliance combustion air inlet

using appropriate hose or pipe.

Direct Vent Appliances are constructed and installed so that

all air for combustion is supplied directly from the outside

atmosphere. The passage for the combustion air is allowed

a small amount of leakage in the building environment. No

special installation considerations are required to use Saf-T

Vent SC on Direct Vent appliances unless speciﬁed by the

appliance manufacturer. Sealed Combustion appliances are

similar to Direct Vent except the combustion air passage must

be sealed to prevent leakage within the building envelope.

When Saf-T Vent SC is used on approved Sealed Combustion

appliances the joints of the outer jacket must be sealed with

a foil tape (example: 3M 425), or approved silicone sealant

(example: Dow Corning 732).

10. Condensate Drains:

When An Internal Condensate Drain is NOT Part of the

Appliance:

•

A Saf-T Vent SC In-Line Drain Section is strongly

recommended. Install this drain ﬁtting as close to the

appliance ﬂue collar as possible.

•

A condensate drain is required for every 30 feet of

horizontal vent and at/near the bottom of a vertical stack.

•

Use the In-Line Drain Section for a straight horizontal or

vertical run. When used horizontally, rotate the ﬁtting so that

the drain tube is as vertical as possible.

•

A Condensate Drain Tube Kit is available to direct the

condensate to an appropriate location, i.e. ﬂoor drain or

vented sanitary sewer connection. A trap loop must be

formed into the drain hose and must be a diameter that is

at least four (4) times the appliance’s rated stack pressure

in inches of water column or 3 inches, whichever is

greater. Secure the loop with a cable tie. Prior to ﬁnal

assembly the trap loop must be ‘primed’ by pouring a

small quantity of water into the drain hose. Inspect at least

annually to verify the trap is ‘primed’.

•

Follow all local and national codes and regulations for the

draining of acidic condensate.

In cold climates do not install a condensate drain on the

exterior of the building. Doing so may result in dangerous

icy conditions on surfaces near the drain and may cause

damage to the vent system and/or the building exterior.

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.

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.

Fire Stop/Wall Thimble/Support, (SC_ _FS):

•The Saf-T Vent SC Fire Stop can be used as a ﬁrestop, a wall thimble, or as a support plate.

•To use as a Wall Thimble prepare an opening according to the chart below. Remove any insulation from the opening,

using additional framing if necessary. Attach the plate over the center of the opening using appropriate fasteners.

•Install the vent section through the thimble plate and secure the section to the thimble by screwing the self-tapping

screws through the holes in the tabs on the plate and into the outer wall of the vent. Apply silicone sealant around the vent

section where it passes through the plate and around the plate where it is attached to the structure.

•To use as a Firestop before passing through ceilings or enclosed chases, prepare a round or square opening ¼” larger than

the outer jacket (5¼” for 3” vent or 7¼” for 4” vent). Remove any insulation from the opening. Secure the ﬁrestop to

the structure at the four (4) corners. Install the vent section through the ﬁrestop and secure to the thimble by screwing the

self-tapping screws through the holes in the tabs on plate and into outer wall of the vent. This method can also be used to

support the vent section either vertically or horizontally.

Tall Cone Flashing:

Directly On Roof or Curb:

Tall Cones are available for ﬂat (SC_ _TCF), 2/12 pitch (SC_ _TCFA), and 6/12 - 12/12 pitch roofs (SC_ _TCFB).

Prepare a square or round opening at least 1/4” larger than the outer jacket (5¼” for 3” vent or 7¼” for 4” vent). Remove

any insulation from the opening. Apply weather-stripping or outdoor caulk to the bottom of the cone plate and attach the

plate to the roof using common construction methods. Flash over the cone plate and seal the fastener heads using normal

rooﬁng requirements. When the vent pipe is in place through the Tall Cone, attach a storm collar (sold separately) around

the pipe. Apply high temperature silicone sealant around the pipe where it passes through the top of the storm collar.

Continue to install vent sections as needed to meet the height requirements by code. Seal weather exposed joints of the

outer jacket with foil tape or an exterior grade silicone sealant.

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.

H. Indoor Air Installation – See Figures 12, 13, 14, 15 and 16.

1. Do not exceed maximum vent length. Refer to

Table 4.

Vertical –

10. Installation of a vertical vent tee 8116304U is

required on all vertical vent applications. See

Figure 6. Attach vertical vent drain tee directly to

elbow or horizontal pipe from an elbow immediately

after vent connector.

Horizontal –

2. Maintain minimum ¼ inch per foot slope in

horizontal runs.

3 Recommended horizontal installation consists of

vent being sloped down away from boiler. See

Figure 12.

11. Install ﬁre stops where vent passes through ﬂoors,

ceilings or framed walls. The ﬁre stop must close

the opening between the vent pipe and the structure.

Fire stop manufacturers are Air-Jet, American Metal

Products, Metal-Fab, and Simpson Dura-Vent.

4. Slope horizontal runs minimum ¼ inch per foot.

Slope towards vertical vent drain tee. Position weld

seams in vent pipes, in all horizontal runs, at the top

to avoid condensate from lying on the seams.

12. Whenever possible install vent straight through roof.

Refer to Figure 13 if offset is necessary. Maintain

minimum clearance to combustible materials.

5. Use appropriately designed thimbles when passing

through combustible walls (thimble use optional

for noncombustible walls). Insert thimble through

wall from outside. Secure outside ﬂange to wall

with nails or screws, and seal with sealant material.

Install inside ﬂange to inside wall, secure with nails

or screws, and seal with sealant material.

13. Install Vent Terminal.

a. Size roof opening to maintain minimum

clearance from combustible materials.

b. Use appropriately designed vent ﬂashing

when passing through roofs. Follow ﬂashing

manufacturers’ instructions for installation

procedures. Flashing manufacturers are Air-

Jet, American Metal Products, Metal Fab, and

Simpson Dura-Vent.

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 twenty-

nine (29) inches from wall when joined to inside

vent piping. See Figure 14.

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.

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.

d. Vertical venting requires ﬂashing and a storm

collar to prevent moisture from entering the

structure.

9. Join vent terminal to 45° elbow included in kit. Join

45° elbow/terminal assembly to vent pipe. Refer

to Section C for proper procedures for joining vent

pipe and ﬁttings. See Figure 3 .

e. Install storm collar on vent pipe immediately

above ﬂashing. Apply Dow Corning Silastic 732

RTV Sealant between vent pipe and storm collar

to provide weathertight seal.

f. Attach vent terminal.

14. Install supplied air intake terminal onto collar of the

jacket enclosure. See Figure 16.

Figure 14: Optional Indoor Air - 3” or 4” Vent Terminal Installation

Figure 15: Indoor Air - Horizontal / Vertical Vent Terminal Installation

Extend Vent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“Y”) distance of twelve

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

Figure 16: Indoor Air - Air Intake Terminal Installation

I. Optional Exterior Separate Horizontal Vent/Air Intake Terminal Mounting – See Figures 17, 18, 19, 20, 21 and 22.

d. At top of vent pipe length install an AL 29-4C^®

90° elbow so that elbow leg is opposite the

building’s exterior surface.

1. Do not exceed maximum vent/air intake lengths.

Refer to Table 4.

2. This installation will allow a maximum of ﬁve (5)

feet vertical exterior run of the vent/air intake piping

to be installed on separate horizontal venting and

indoor air horizontal venting.

e. If installation requires indoor air, install

AL 29-4C^®45° elbow (provided in indoor air kit)

to upper AL 29-4C^®90° elbow so that leg of 45°

is in down direction (see Figure 21 or 22). If not

using indoor air, proceed to Step f.

NOTICE

f. Install horizontal vent terminal (provided with

boiler).

Exterior run to be included in equivalent

vent/air intake lengths.

g. Brace piping if required.

3. Install vent piping.

4. Air Intake Piping (not required for indoor air).

a. Install vent piping for desired venting system.

Refer to speciﬁc section for details for vent pipe

installation.

a. Install air intake piping for desired venting

system. Refer to speciﬁc section for details for

air intake installation.

b. After penetrating wall/thimble, install an

AL 29-4C^®90° elbow so that elbow leg is in the

up direction.

c. Install maximum of ﬁve (5) feet of AL 29-4C^®

vent pipe. Refer to Sections C through E for

proper procedures for joining vent pipe and

ﬁttings.

b. After penetrating wall, install a corrosion

resistant 90^oelbow so that elbow leg is in the up

direction.

c. Install maximum of ﬁve (5) feet of corrosion

resistant air intake pipe.

d. At top of air intake pipe install air intake

terminal (provided with boiler).

e. Brace piping if required.

Figure17: Optional Separate Horizontal Air 3” or 4” Intake Terminal Installation

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

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)

Figure 22: Optional Separate Horizontal 4” Vent Terminal Installation (Indoor Air)

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.

addition, some jurisdictions require the use of a LWCO

with a hot water boiler.

A. Design and install boiler and system piping to

prevent oxygen contamination of boiler water and

frequent water additions.

Where

1. There are many possible causes of oxygen

contamination such as:

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.

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

of system leaks.

b. Absorption through open tanks and ﬁttings.

c. Oxygen permeable materials in the distribution

system.

What Kind

The SCG boiler is designed to accept the wiring of the

Safgard Model 1100-H4 (P/N 45-1104) LWCO. This is

a probe type LWCO. The factory wiring is designed to

allow simple “Plug-in” installation of the wiring.

2. In order to insure long product life, oxygen sources

must be eliminated. This can be accomplished by

taking the following measures:

a. Repairing system leaks to eliminate the need for

addition of make-up water.

b. Eliminating open tanks from the system.

c. Eliminating and/or repairing ﬁttings which allow

oxygen absorption.

How to Pipe

A “tee” is commonly used to connect the probe LWCO

to the supply or return piping, as shown below.

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)

WARNING

DO NOT ATTEMPT to cut factory wires to

install an aftermarket Low Water Cut Off

(LWCO). Only use connections

specifically identified for Low Water Cut

Off.

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.

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 ﬂoor level as the boiler). In

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.

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.

How to Wire

Ensure power is turned off to boiler.

Locate the LWCO jumper wire in the factory wiring

harness. Remove the jumper wire and install

the LWCO wiring from LWCO Model 1100-H4

(P/N 45-1100) into the plug of the SCG factory wiring.

How to Test

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.

Shut off fuel supply. Lower water level until water

level is BELOW the LWCO. Generate a boiler demand

by turning up thermostat. Boiler should not attempt to

operate. Increase the water level by ﬁlling the system.

The boiler should attempt to operate once the water

level is above the LWCO.

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

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.

H. If boiler is connected to heating coils located in

air handling units where they may be exposed to

refrigerated air, boiler piping must be equipped with

ﬂow control valves to prevent gravity circulation of

boiler water during operation of cooling system.

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.

NOTICE

Burnham recommends sizing the system

circulator to supply sufficient flow (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 ﬂanges, gaskets and bolts

provided. Circulator harness allows circulator to be

mounted on supply or return. Connect harness to

circulator and secure any excess conduit.

Figure 23: Recommended Piping for Combination

Heating & Cooling (Refrigeration) System

E. Install supply manifold, pressure/temperature gauge

and pressure relief valve.

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.).

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 24: Supply Water Manifold Piping

Install pipe tee between circulator and boiler return

L. Oil, grease, and other foreign materials which

accumulate in new hot water boilers and a new

or reworked system should be boiled out, and

then thoroughly ﬂushed. A local qualiﬁed water

treatment chemical specialist is a suggested source

for recommendations regarding appropriate chemical

compounds and concentrations which are compatible

with local environmental regulations.

along with second tee in supply piping as shown in

Figure 25 or 26. Bypass should be same size as the

supply and return lines with valves located in bypass

and supply outlet as illustrated in Figure 25 or 26 in

order to regulate water ﬂow to maintain higher boiler

water temperatures.

After the boiler is operational (reference Section VIII.

System Start-Up) set by-pass and boiler supply valves

to half throttle position to start. Operate boiler until

system water temperature reaches normal operating

range.

M. After the boiler and system have been cleaned and

ﬂushed, and before reﬁlling the entire system add

appropriate water treatment chemicals, if necessary, to

bring the pH between 7 and 11.

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.

N. If it is required to perform a long term pressure

test of the hydronic system, the boiler should ﬁrst be

isolated to avoid a pressure loss due to the escape of air

trapped in the boiler.

J. A hot water boiler installed above radiation level

must be provided with a low water cutoff device as part

of installation.

To perform a long term pressure test including the

boiler, ALL trapped air must ﬁrst be removed from the

boiler.

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.

A loss of pressure during such a test, with no visible

water leakage, is an indication that the boiler contained

trapped air.

V. Gas Piping

WARNING

4. Speciﬁc gravity of gas. Gas piping systems for

gas with a speciﬁc gravity of 0.70 or less can be

sized directly from Table 7, unless authority having

jurisdiction speciﬁes a gravity factor be applied.

For speciﬁc gravity greater than 0.70, apply gravity

factor from Table 6. If exact speciﬁc gravity is not

shown choose next higher value.

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.

Table 6: Speciﬁc Gravity Correction Factors

An additional gas pressure regulator may

be needed. Consult gas supplier.

Specific

Gravity

Correction

Factor

Specific

Gravity

Correction

Factor

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

----

0.85

0.90

1.00

1.10

1.20

1.30

1.40

0.81

0.82

0.78

0.74

0.71

0.68

0.66

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.

0.60

0.65

0.70

0.75

0.80

1.00

0.96

0.93

0.90

0.87

2. Maximum gas demand. Refer to the boiler’s input

as printed on it’s rating label. Also consider existing

and expected future gas utilization equipment (i.e.

water heater, cooking equipment).

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, NFPA54/ANSI

Z223.1, or size system using standard engineering

methods acceptable to authority having jurisdiction.

3. Length of piping and number of ﬁttings. Refer to

Table 7 for maximum capacity of Schedule 40 pipe.

Table 8 lists equivalent pipe length for standard

ﬁttings.

Table 5: Gas Ratings

Natural/LP

Maximum

Gas Pressure

(in. w.c.)

Minimum Natural

Gas Pressure

(in. w.c.)

Minimum LP

Gas Pressure

(in. w.c.)

Natural

Manifold

Pressure

(in. w.c.)

Boiler

Model

Number

Manifold

Pressure

(in. w.c.)

Inlet to Gas Valve Inlet to Gas Valve

SCG-3

SCG-4

SCG-5

SCG-6

SCG-7

SCG-8

SCG-9

4.5

11.5

3.5

10.5

NOTICE

SCG boilers built for altitudes greater than 4,999 feet above sea level need to be specially

orificed to adjust for changes in atmospheric conditiions. The SCG boiler "H" Model has been

certified to operate in atmospheric conditions from 5,000 to 10,000 feet above sea level. Input is

derated by 10% for applications at 5,000 feet above sea level, and 20% for applications at 10,000

feet above sea levels. Derate is based on 2% reduction per 1000 feet.

The SCG boiler is available in two (2) altitude Models: The "S" Model 0-4,999 feet above sea

level, and the "H" Model 5,000-10,000 feet above sea level.

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

Table 7: Maximum Capacity of Schedule 40 Pipe in CFH* For Gas Pressures of 0.5 psig or Less

0.3 inch w.c. Pressure Drop

0.5 inch w.c. Pressure Drop

Length

[Feet]

132

1¼

1,050

730

590

500

440

400

370

350

320

305

175

120

1¼

1,400

950

770

660

580

530

490

460

430

400

100

278

190

152

130

115

105

520

350

285

245

215

195

180

170

160

150

360

250

200

170

151

138

125

118

110

103

680

465

375

320

285

260

240

220

205

195

* 1 CFH of Natural Gas is approximately equal to 1 MBH; 1 CFH of LP is approximately equal to 2.5 MBH; con-

tact your gas supplier for the actual heating value of your gas.

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

flammable 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 liqueﬁed petroleum gas.

3. Install sediment trap, ground-joint union and manual

shut-off valve upstream of boiler gas control valve

Figure 27: Recommended Gas Piping

and outside jacket. See Figure 27.

Table 8: Equivalent Lengths of Standard Pipe Fittings & Valves

VALVES FULLY OPEN

Pipe

Size

I. D.

Inches

Swing

90°

45°

Elbow

90° Tee, Flow

Through Run

90° Tee, Flow

Through Branch

Gate Globe Angle Check Elbow

½"

¾"

0.622

0.824

1.049

1.380

0.35

0.44

0.56

0.74

18.6

23.1

29.4

38.6

9.3

4.3

5.3

6.8

8.9

1.6

2.1

2.6

3.5

0.78

0.97

1.23

1.60

1.0

1.4

1.8

2.3

3.1

4.1

5.3

6.9

11.5

14.7

19.3

1¼"

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.

piping by closing boiler’s individual manual shutoff

valve.

2. Locate leaks using approved combustible gas

detector, soap and water, or similar nonﬂammable

solution.

C. Pressure test. The boiler and its gas connection must

be leak tested before placing boiler in operation.

DANGER

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

Do not use matches, candles, open flames

or other ignition source to check for leaks.

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.

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.

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

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.

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

D. System Controls and Wiring

1. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.

2. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes.

3. Use armored cable (BX) over all exposed line voltage wiring.

4. If an Alliance™ indirect water heater is used, use priority zoning except for Hydro-Air Systems.

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

Set the thermostat heat anticipator to 0.60 amps.

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

for this type of system.

Set the thermostat heat anticipator to 0.60 amps.

7. Conventional Circulator Zoned System – Refer to Figure 32 of this manual for the electrical diagram for this type of

system.

Read, understand and follow all of the instructions provided with the Honeywell R8888 control.

Connect the thermostat of each zone and the circulator for that zone to R8888 panel. If an Alliance™ indirect water

heater is used, connect the Alliance™ thermostat and circulator to the Zone 1 terminals of the R8888.

Set the thermostat heat anticipator to 0.12 amps.

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 first zone of the main control, will provide priority

circulation. If more than four (4) zones are required, connect additional R8888's by wiring the A,

B, and C terminals of each control together. 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 first R8888 and set

the panel type switch to "expansion" on the second, third or fourth R8888.

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

in Figure 34.

Connect the thermostat of each zone and the zone valve for that zone to the R8889 control. If an Alliance™ indirect water

heater is used, connect the Alliance™ thermostat and zone valve to the “zone 1” terminals of the R8889.

Set the thermostat heat anticipator to 0.12 amps.

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 first 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 first R8889 and set the panel type switch to "expansion" on the

second, third or fourth R8889.

NOTICE

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

drawing below.

Figure 34: Different Manufacturer’s Zone Valve Connections to Honeywell R8889

VII. Modular Installation

with vertical venting and sidewall combustion air

inlet (or visa versa) if installation conditions do not

allow alternate arrangement.

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.

Table 9: Modular Boiler Water Manifold Sizing

Recommended Minimum

2. Consult Local Building Codes or National Fuel Gas

Code, NFPA 54/ANSI Z222.3 for restrictions and

instructions on modular boiler installations.

Combined Output

Common Water Manifold

(MBH)

Size (NPT)

< 166

< 260

< 550

< 900

< 2000

1¼"

1½"

B. Module Sizing

Burnham recommends sizing each boiler in a modular

system to provide 20 % of the combined heating load

where ever possible.

2½"

C. Venting

1. Each boiler must have an individual vent pipe.

Refer to Venting Section of this manual for venting

guidelines and options.

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.

WARNING

Do not manifold vent pipes together.

F. Gas Piping

2. The maximum vent length for each boiler is ﬁfty

1. Refer to National Fuel Gas Code, Local Codes and

Tables 7 and 8 for gas pipe sizing.

(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.

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.

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.

G. Electrical

1. Each boiler must be provided with a fused

disconnect and service switch.

D. Air Intake Piping

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.

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

H. Modular Boiler Control Systems

ﬁfty (50) equivalent feet.

Contact a controls manufacturer such as Honeywell or

Tekmar to properly apply a modular control system.

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

Common systems may use outdoor temperature, return

water temperature or both to stage the boilers.

VIII. System Start-up

4. Starting with one circuit at a time, open zone valve

or shut-off valve in system supply and return piping.

A. Safe operation and other performance criteria were

met with gas manifold and control assembly provided

on boiler when boiler underwent tests speciﬁed in

American National Standard for Gas-Fired Low-

Pressure Steam and Hot Water Boilers, ANSI Z21.13.

5. Open hose bib.

6. Open ﬁll valve (Make-up water line should be

located directly after full port ball valve in system

supply piping between air scoop and expansion

tank).

B. Verify that the venting, water piping, gas piping and

electrical system are installed properly. Refer to

installation instructions contained in this manual.

7. Allow water to overﬂow from bucket until discharge

from hose is bubble free for 30 seconds.

C. Conﬁrm all electrical, water and gas supplies are

turned off at the source and that vent is clear of

obstructions.

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.

D. Conﬁrm that all manual shut-off gas valves between

the boiler and gas source are closed.

WARNING

9. Close hose bib, continue ﬁlling the system until the

pressure gauge reads 12 psi. Close ﬁll valve.

Completely read, understand and follow all

instructions in this manual before

attempting start up.

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

pressure reducing valve, system will automatically

ﬁll to 12 psi. Follow ﬁll valve manufacturer’s

instructions).

E. Fill entire heating system with water and vent air

from system. Use the following procedure on a Series

Loop or multi-zoned system installed as per Figure 25

or 26 to remove air from system when ﬁlling.

10.Open isolation valve in boiler supply piping.

11. Remove hose from hose bib.

F. Conﬁrm that the boiler and system have no water

WARNING

leaks.

The maximum operating pressure of this

boiler is 30 psig. Never exceed this

pressure. Do not plug or change pressure

relief valve.

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.

NOTICE

3. Temporarily turn off all other gas-ﬁred appliances.

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

If it is required to perform a long term

pressure test of the hydronic system, the

boiler should first be isolated to avoid a

pressure loss due to the escape of air

trapped in the boiler.

To perform a long term pressure test

including the boiler, ALL trapped air must

first be removed from the boiler.

5. Conﬁrm that the supply pressure to the gas valve is

14 in. w.c. or less. Refer to Table 5 for minimum

supply pressure.

6. Open the ﬁeld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

7. Using soap solution, or similar non-combustible

solution, electronic leak detector or other approved

method. Check that boiler gas piping valves, and

all other components are leak free. Eliminate any

leaks.

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).

DANGER

Do not use matches, candles, open flames

or other ignition source to check for leaks.

3. Attach a hose to the vertical hose bib located prior to

the full port ball valve in the system supply piping.

(Note - Terminate hose in ﬁve gallon bucket at a

suitable ﬂoor drain or outdoor area).

8. Purge gas line of air.

Figure 36: Operating Instructions

Figure 38: 1 Inch Main Burner ﬂame

Figure 39: Pilot Burner Flame

K. Check main burner ﬂame. See Figures 38. Flame

should have clearly deﬁned inner cone with no yellow

tipping. Orange-yellow streaks should not be confused

with true yellow tipping.

L. Check thermostat operation. Raise and lower

temperature setting to start and stop boiler operation.

M. Check ignition control module shut-off. Disconnect

pilot lead wires from gas valve. If burners do not

shutdown, determine cause of malfunction. Replace

necessary items and check operation.

Figure 37: Sequence of Operation

N. Check low water cutoff (if so equipped).

H. Follow Operating Instructions to place boiler in

1. Adjust thermostat to highest setting.

operation. See Figure 36.

2. With boiler operating, open drain valve and slowly

drain boiler.

I. Sequence of Operation. See Figure 37. If boiler fails

to operate properly, see Troubleshooting Tree in Section

IX: Service.

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.

J. Check pilot burner ﬂame. See Figure 39. Flame

should be steady, medium hard blue enveloping 3/8 to

½ inch of sensing probe.

4. Adjust thermostat to lowest setting. Reﬁll boiler.

more than 0.3 inch w.c. If measured input rate is

still less than 98% of rated input:

O. Check limit.

1. Adjust thermostat to highest setting.

i. Remove Main Burners per procedure in

Section IX: Service.

ii. Remove gas oriﬁces. Drill one (1) drill size

larger (drill size is stamped on oriﬁce, or see

Section X: Repair Parts).

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.

iii. Reinstall gas oriﬁces and main burners.

Measure input rate.

4. Adjust thermostat to lowest setting. Adjust limit to

desired setting.

6. Recheck Main Burner Flame.

7. Return other gas-ﬁred appliances to previous

P. Adjust gas input rate to boiler.

conditions of use.

1. Adjust thermostat to highest setting.

Q. Review User’s Information Manual and system

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.

operation with owner or operator.

Table 10: Gas Flow Rate in Cubic Feet

Per Hour

Size of Gas Meter Dial

Seconds

for One

Revolution

One-Half

Cu. Ft.

One

Cu. Ft.

Two

Cu. Ft.

120

113

106

100

240

225

212

200

189

180

172

164

157

150

144

138

133

129

124

120

3. Clock gas meter for at least 30 seconds. Use Table

10 to determine gas ﬂow rate in Cubic Feet per

Hour.

WARNING

Failure to properly adjust gas input rate will

result in over firing or under firing of the

appliance. Improper and unsafe boiler

operation may result.

4. Determine Input Rate. Multiply gas ﬂow rate by gas

heating value.

5. Compare measured input rate to input rate stated on

rating plate.

a. Boiler must not be over ﬁred. Reduce input rate

by decreasing manifold pressure. Do not reduce

more than 0.3 inch w.c. If boiler is still overﬁred,

contact your Burnham distributor or Regional

Ofﬁce for replacement Gas Oriﬁce.

b. Increase input rate if less than 98% of rating

plate input. Increase manifold gas pressure no

IX. Service

DANGER

This boiler uses flammable 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.

4. Pipe must be supported at minimum ﬁve (5) foot

A. General. Inspection and service should be conducted

annually. Turn off electrical power and gas supply while

conducting service or maintenance. Follow instructions

TO TURN OFF GAS TO APPLIANCE. See Figure 37.

intervals and must not sag.

5. All vent joints must be secure and watertight.

6. All air intake joints must be secure and airtight.

Horizontal vent tee drain or vertical vent tee drain

(if used) must have minimum 6 inch trap and allow

condensate to ﬂow freely. To Clean:

B. Low water cutoff (if so equipped).

Probe Type (Annual Service). Probe type LWCO

should be removed once a year, examined and

cleaned of any dirt accumulations to assure proper

operations. Do not attempt to repair mechanisms in the

ﬁeld. Complete replacement mechanisms, including

necessary gaskets and installation instructions, are

available from the manufacturer.

a. Disconnect drain tube from drain ﬁtting.

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

c. Securely fasten drain tube to drain ﬁtting,

providing gas-tight and watertight seal.

7. If pipe must be disassembled for removal of

obstructions or resealing of joint, see Section III,

Paragraph C.

C. Vent/Air Intake System. Inspect for obstructions, soot

accumulation, proper support, and deterioration of pipe,

ﬁttings, and joints.

D. Boiler Flue Passages. Inspect for blockage or soot

accumulation.

1. Clean terminal screens. Terminals must be free of

obstruction, undamaged, with screens securely in

place.

1. Remove Main Burners. See Figure 42.

a. Remove front door.

2. Terminal and wall thimbles (if used) must be

weathertight.

b. Remove air intake box front door.

i. Remove sheet metal screws.

3. Pipe must be full round shape, and show no damage

from impact or excessive temperature.

c. Disconnect pilot tubing and pilot lead wires at

the gas valve.

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 oriﬁce. Burner which holds pilot

can be removed by lifting the burner adjacent to

its right ﬁrst.

2. Disconnect Vent Connector and Vent Pipe from

Blower Outlet

3. Remove Jacket Top Panel.

Figure 41: Blower Vent Connector Assembly

4. Disconnect the Black and Gary Silicone Tubing

from the Canopy.

13. Install Jacket Top Rear Panel.

5. Disconnect Wiring Harness from Blower Motor.

6. Remove Canopy/Blower Assembly.

14. Connect Vent System. See Figure 41.

15. Connect Blower Motor Wiring Harness.

a. Loosen the (4) screws from Canopy.

E. Main Burners and Firebox.

7. Remove Flue Gas Bafﬂes. Inspect Flue Gas Bafﬂes

for deterioration.

1. Vacuum ﬁrebox. Exercise care - do not damage base

insulation.

8. Inspect ﬂue passages. Clean with ﬂue brush. See

Figure 42.

2. Clean main burners. Brush top of burners with soft

bristle brush. See Figure 42. Vacuum to remove any

dirt and lint.

9. Inspect heating surface in combustion chamber.

Clean with straight handle wire brush.

10. Install Flue Gas Bafﬂes.

3. Vacuum tip of pilot burner.

11. Replace Canopy/Blower Assembly.

4. Check gas oriﬁces for lint and dirt. Clean as

12. Connect Silicone Tubing between Pressure Fittings

on Canopy Assembly and Pressure Switch. Route

through bushings in Vestibule Panel . See Figure

40.

necessary.

5. Install main burners by reversing procedure to

remove burners.

a. Pilot burner must be installed in original

location. See Table 11.

b. Main burners must be properly secured in burner

tray slot at rear of ﬁrebox and over gas oriﬁce.

See Figure 42.

c. Pilot gas supply and pilot lead wires must be

reconnected.

d. Burner access panel must be securely in place.

e. Reinstall air diffuser screen.

f. Reconnect Flame Roll-out wires.

g. Air Intake Box Front Door must be installed.

F. Check operation. Follow steps G through P from

Section VIII: System Start-up.

Figure 40: Silicone Tubing Assembly

Table 11: Pilot Burner Location

Boiler Model

SCG-3

Main Burner with Pilot Bracket

Pilot Burner Located Between Main Burners *

2 & 3

3 & 4

4 & 5

5 & 6

6 & 7

7 & 8

8 & 9

SCG-4

SCG-5

SCG-6

SCG-7

SCG-8

SCG-9

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

G. Procedure for Measuring Differential Pressure (See

Figure 43).

1. With boiler off, remove Gray and Black Hoses at

differential pressure switch.

2. With tees and ¼ inch aluminum stubs, connect water

manometer as shown with additional tubing.

3. Start boiler and read Pressure on Manometer

when boiler water temperature reaches operating

temperature. Refer to Table 12 for minimum

readings.

NOTE: If switch drops-out before boiler reaches

temperature or if pressure differential readings are

below minimums shown in Table 12, check for

cracks in hose or contact your nearest Burnham

representative.

4. Stop boiler, remove manometer and reconnect hoses

to differential pressure switch. See Figures 40 and

43.

Figure 43: Differential Pressure Measurement

Table 12: Differential Pressure Switch Settings

Minimum Differential Pressure

Boiler Model

Sea Level to 4,999 Ft.

5,000 - 10,000 Ft. Elevation

SCG-3

SCG-4

SCG-5

SCG-6

SCG-7

SCG-8

SCG-9

1.32" w.c.

1.17" w.c.

.88" w.c.

.80" w.c.

.88" w.c.

.80" w.c.

.65" w.c.

.35" w.c.

.30" w.c.

.35" w.c.

XI. Repair Parts

All SCG Repair Parts may be obtained through your local Burnham Wholesale distributor.

Should you require assistance in locating a Burnham distributor in your area, or have questions

regarding the availability of Burnham products or repair parts, please contact Burnham

Customer Service at (717) 481-8400 or Fax (717) 481-8408.

[Quantity] Part Number

Key

No.

Description

SCG-3

SCG-4

SCG-5

SCG-6

SCG-7

SCG-8

SCG-9

1. CASTING ASSEMBLY

Section Assembly

61707031

61707041

61707051

51707061

71707001

61707071

61707081

61707091

1A Left End Section

1B Center Section

1C Right End Section

1D Slip Nipple, #3

(1)

71707003

(2)

71707003

(3)

71707003

(4)

71707003

(5)

71707003

(6)

71707003

(7)

71707003

71707002

(10)

(4)

(6)

(8)

(12)

(14)

(16)

806600009 806600009 806600009 806600009 806600009 806600009 806600009

(2)

71107002

(3)

71107002

(4)

71107002

(5)

71107002

(6)

71107002

(7)

71107002

(8)

71107002

1E Flue Gas Baffle

(2)

1F Tie Rod, ¼"-20

1G Hex Nut, ¼"-20

100109-01 100108-05 100108-07 100108-13 100108-14 100108-15 100108-16

(4) 80860407

[Quantity] Part Number

SCG-5 SCG-6 SCG-7

Key

No.

Description

SCG-3

SCG-4

SCG-8

SCG-9

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

2D Base Front Panel

61807031 61807041 61807051 61807061 61807071 61807081 61807091

71807035 71807045 71807055 71807065 71807075 71807085 71807095

2E Burner Access Panel

2F Cerafelt Gasket 1/2" x 2"

2G Cerafelt Gasket 1/2" x 2"

2H Base Side Insulation

2J Base Rear Insulation

2K Base Front Insulation

2L Base Leg Assembly

2M Self Tapping Screw, 1/4"-20 x 1/2"

2N Flame Roll-out Switch

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

2Q Self Tapping Screw, 10-32 x 3/8"

71807036 71807046 71807056 71807066 71807076 71807086 71807096

6206002

(2) 72007001

72007031 72007041 72007051 72007061 72007071 72007081 72007091

72007032 72007042 72007052 72007062 72007072 72007082 72007092

(4) 6186001

(18) 80860700

80160044

80860030

(5) 80860705

(6) 8086070

(4) 80860717

(7) 8086070

Seft Tapping Screw Hex Cap,

5/16 -18 x 3/4"

[Quantity] Part Number

SCG-5 SCG-6 SCG-7

Key

No.

Description

SCG-3

SCG-4

SCG-8

SCG-9

3. BASE ENCLOSURE ASSEMBLY

3A Air Box Assembly

61807032 61807042 61807052 61807062 61807072 61807082 61807092

71807034 71807044 71807054 71807064 71807074 71807084 71807094

3B Air Box Door

3C Combustion Air Diffuser

3D Pilot Tube Gasket Cover Plate

3E Pilot Tube Gasket

N/A

71807049 71807059 71807069 71807079 71807089 71807099

7096002

8206038

3F Observation Port Gasket

3G Observation Port Lens

(2) 8206039

8026082

3H Observation Port Lens Retainer

3J Sheet Metal Screws #8 x 1/2"

3K Self Tapping Screw, 10-32 x 3/8"

7186019

(10) 80860000

(18) 80860705

(22) 80860705

[Quantity] Part Number

SCG-5 SCG-6 SCG-7

Key

No.

Description

SCG-3

SCG-4

SCG-8

SCG-9

4. FAN/CANOPY ASSEMBLY

Canopy Assembly - Sea Level

61107031 61107041 61107051 61107061 61107071 61107081 61107091

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

4B Cerafelt

9206005

(4) 80861512

(4) 80860013

8206085

4C U-Clip

4D Sheet Metal Screw, #10 x 3/4"

4E Fan Gasket

4F Fan

81161512

4G Lock Washer, #10

4H Machine Screw, #10-24 x 2-1/2"

(4) 80860636

(4) 808608982

[Quantity] Part Number

SCG-6 SCG-7

SCG-5

Key

No.

Description

SCG-8

SCG-9

SCG-3

SCG-4

5. BURNER ASSEMBLIES

Gas Valve (Natural Gas),

Honeywell VR8204P1171

81660282

N/A

Gas Valve (Natural Gas),

Honeywell VR8304P4496

N/A

81660146

N/A

81660283

N/A

Gas Valve (LP Gas),

Honeywell VR8204C3015

Gas Valve (LP Gas),

Honeywell VR8304P4280

81660181

Nipple, ½" NPT x Close

806600040

N/A

Nipple, ¾" NPT x Close

806600022

N/A

Union, ½" NPT

506604023

N/A

Union, ¾" NPT

806604001

Gas Manifold

82207031 82207041 82207051 82207061 82207071 82207081 82207091

¾" Gas Manifold

(4)

822710

(6)

822710

(8)

822710

(10)

822710

(12)

822710

(14)

822710

(16)

822710

Burner Orifices - Natural Gas #47

(4)

822792

(6)

822792

(8)

822792

(10)

822792

(12)

822792

(14)

822792

(16)

822792

Burner Orifices - LP Gas 1.20 mm

Pilot Assembly - Natural Gas

8236163

8236164

100147-01

(9)

Pilot Assembly - LP Gas

Pilot Burner

Main Burner

(3)

(5)

(7)

(11)

(13)

(15)

100146-01 100146-01 100146-01 100146-01 100146-01 100146-01 100146-01

Pilot Tubing

8236122

Self Tapping Screw, 1/4-20 x1/2"

(6) 80860700

[Quantity] Part Number

Key

No.

Description

SCG-3

SCG-4

SCG-5

SCG-6

SCG-7

SCG-8

SCG-9

6. CONTROL PANEL ASSEMBLY

Limit, Honeywell L4080D

80160156

Transformer/Relay, Honeywell R8285D

80160155U

Ignition Module, Honeywell

S8670E1007

80160108

Blower Relay, Honeywell R8222U1006

80160096U

Differential Pressure Switch

Sea Level 0' - 4999'

80160762

80160759

80160761

80160763

80160760 80160759

80160760

80160764

High Altitude - 5000' - 10,000'

Junction Box

80160764 80160765

8136259

[Quantity] Part Number

Key

No.

Description

SCG-3

SCG-4

SCG-5

SCG-6

SCG-7

SCG-8

SCG-9

7. JACKET PARTS

Jacket Left Side Panel

60407002

60407001

Jacket Right Side Panel

Rear Panel

60407033 60407043 60407053 60407063 60407073 60407083 60407093

60407034 60407044 60407054 60407064 60407074 60407084 60407094

60407032 60407042 6040752 60407062 60407072 60407082 60407092

70407031 70407041 70407051 70407061 70407071 70407081 70407091

Vestibule Panel

Top Panel

Front Door

7G Air Intake Collar Assembly

7H Handle

60407003

60407004

8056184

60407005

Door Clip

(2) 7041921

8136048

Bushing

Burnham Logo

81460099

[Quantity] Part Number

Key

No.

Description

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

8. MISCELLANEOUS PARTS CARTON

Water Manifold

80607001

8056169

Temperature/Pressure Gauge

Circulator Wiring Harness

Safety Relief Valve

Boiler Drain Valve

Vent Terminal

6130701

81660363

806603061

8110701

6116044

8110703

8110702

6116063

8110704

Air Intake Terminal

Vent Connector

6116045

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

This product contains refractory ceramic ﬁbers (RCF). RCF has been classiﬁed as a

possible human carcinogen. After this product is ﬁred, RCF may, when exposed to

extremely high temperature (>1800F), change into a known human carcinogen. When

disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may

be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace previously ﬁred RCF (combustion chamber insulation, target

walls, canopy gasket, ﬂue cover gasket, etc.) or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved

respirator

2. Long sleeved, loose ﬁtting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing machine

after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an air tight plastic bag.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water. Seek

immediate medical attention if irritation persists.

• If breathing difﬁculty develops: Leave the area and move to a location with

clean fresh air. Seek immediate medical attention if breathing difﬁculties

persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate

medical attention.

SERVICE RECORD

DATE

SERVICE PERFORMED

SERVICE RECORD

DATE

SERVICE PERFORMED

Limited Warranty

FOR RESIDENTIAL CAST IRON WATER BOILERS

water boiler for its intended purposes and its maintenance

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:

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.

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.

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.

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:

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.

Years

In Service

1-10

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

Service Charge

as % of

Charge

Retail Price

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.

Years

In Service

25 and

above

Service Charge

as % of

Retail Price

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.

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.

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.

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.

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.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND

YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE

TO STATE.

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

03/03

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