Page 2 - IMPORTANT INFORMATION - READ CAREFULLY; shall be consulted before installations are made.; DANGER
IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted be...
Page 3 - installation is complete.
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 bef...
Page 4 - Table of Contents; Figure 1: Minimum Clearances to Combustibles
4 Table of Contents Figure 1: Minimum Clearances to Combustibles I. Pre-Installation ............................... 6 II. Unpack Boiler ................................ 7 III. Venting/Air Intake Piping .............. 8 IV. Water Piping and Trim ................. 45 V. Gas Piping ......................
Page 5 - Figure
Page 7 - unconfined space in building; CAUTION
7 c. Horizontal ducts. Minimum free area of one (1) square inch per 2,000 Btu per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area. Alternate method for boiler located within confined space. Use indoor air if two permanent openings communicate direct...
Page 8 - TABlE 1: AIR INTAkE / VENT SySTEM OPTIONS; WARNING
8 III. Venting / Air Intake Piping TABlE 1: AIR INTAkE / VENT SySTEM OPTIONS WARNING Do not use this boiler with galvanized, Type 04 or Type 1 stainless steel, non metallic or any other non Al9-4C ® based vent systems. Do not use a barometric damper or drafthood with this appliance.Do not use vent d...
Page 10 - General Guidelines; National Fuel Gas Code
10 A. Vent Guidelines Due to Removal of an Existing Boiler For installations not involving the replacement of an existing boiler, proceed to Step B. When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remainin...
Page 11 - Install Vent Pipe, Burnham Gasketed Vent System.
11 with at least one side open, similar to a joist bay application. Use double wall thimble [Burnham Part No. 8116115 (3”), 100185-01 (4”)] when penetrating a combustible wall. 9. Do not install venting system components on the exterior of the building except as specifically required by these instru...
Page 12 - Separate Horizontal Venting System.; Vent Piping
1 a. Wipe the male end of each joint using an alcohol pad to remove any dirt and grease. b. Align weld seams in pipes and use a slight twisting motion to FULLY insert male end into female end of joint. Ensure bead in male end of pipe is below locking band and rest against the end of the female pipe....
Page 15 - Figure 5A: Separate Horizontal – V
15 Figure 5A: Separate Horizontal – V ent/Air Intake T erminal Configuration (SCG-3 thru 7)
Page 16 - Figure 5B: Separate Horizontal – V
1 Figure 5B: Separate Horizontal – V ent/Air Intake T erminal Configuration (SCG-8 and 9)
Page 17 - Vertical Venting; Vertical venting requires the use of roof flashing; Vertical Air Intake Piping; E. Separate Vertical Venting System; NOTICE; Roof penetrations require the use of roof flashing
17 Vertical Venting – 1. See Figure 43 on Page 72 for Blower Vent Connector Assembly. Do not exceed maximum vent lengths. Refer to Table 4. 2. Installation of a vertical vent drain tee 8116304U is required on all vertical vent applications. See Figures 6 and 7. Attach vertical vent drain tee directl...
Page 20 - Extend V
0 Figure 8A: V ertical V ent/Air T ermination ( ” V ent T erminal) Extend V ent/Air Intake Piping to maintain minimum vertical (“X”) and minimum horizontal (“ y”) distance of twelve (1 ) inches from roof surface. Allow additional vertical (“X”) distance for expected snow accumulation.
Page 22 - Figure 9: Vertical Air Intake Piping
Page 23 - This vent system requires components not; Vent Carton Part Number 61106012 (Includes Items Below); C 4” x 3” Vent Pipe Reducer
COMBINATION hORIZONTAl VENT SySTEM COMPONENTS 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. 2. Install Combination Vent/Air Terminal. See Figure 11. a. After determining the location wit...
Page 24 - Install Vent Piping
4 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. d. Drill four (4) pilot holes, properly sized ...
Page 27 - Combination Vertical Venting System; Description; Vent Carton Part Number; COMBINATION VERTICAl VENT SySTEM COMPONENTS
7 G. Combination Vertical Venting System – SCG-3 Through SCG-6 ONLY – See Figures 12, 13 and 14. NOTICE This vent system requires components not supplied with the boiler. Description Part Number SCG-3 & SCG-4 SCG-5 & SCG-6 Vent Carton Part Number 100222-01 100223-01 Air Intake Tee 100224-01 ...
Page 28 - must; ClEARANCES TO COMBUSTIBlES:
8 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 finis...
Page 30 - Joint Assembly Instructions:; overlap the male end 1”.; short pot rivet can be used.
0 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 ...
Page 32 - Air Intake Connections for Direct Vent and Sealed
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 adapter...
Page 33 - Horizontal Supports:; consider clearances when planning the system.
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...
Page 34 - Support Legs Rotated Horizontally:; connection. The legs can be cut to shorter lengths if necessary.
4 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...
Page 35 - support the vent section either vertically or horizontally.; Directly On Roof or Curb:
5 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. Atta...
Page 36 - connected directly to the vertical termination adapter.; Seal weather exposed joints of the outer jacket with foil tape or
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. ...
Page 37 - Install Vent Terminal.; Vent Terminal and Air Intake Terminal; Indoor Air Installation –
7 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. 12. Whenever possible install vent straig...
Page 41 - Exterior run to be included in equivalent vent/air; Air Intake Piping
41 1. Do not exceed maximum vent/air intake lengths. Refer to Table 4. 2. This installation will allow a maximum of seven (7) feet vertical exterior run of the vent/air intake piping to be installed on separate horizontal venting and indoor air horizontal venting. NOTICE Exterior run to be included ...
Page 45 - DO NOT ATTEMPT to cut factory wires to; IV. Water Piping and Trim; lWCO location
45 A. Design and install boiler and system piping to prevent oxygen contamination of boiler water and frequent water additions.1. There are many possible causes of oxygen contamination such as:a. Addition of excessive make-up water as a result of system leaks. b. Absorption through open tanks and fi...
Page 47 - Figure 4: Supply Water Manifold Piping
47 Figure 4: Supply Water Manifold Piping Install pipe tee between circulator and boiler return along with second tee in supply piping as shown in Figure 25 or 26. Bypass should be same size as the supply and return lines with valves located in bypass and supply outlet as illustrated in Figure 25 or...
Page 50 - Size gas piping
50 V. Gas Piping TABlE 5: GAS RATINGS TABlE : SPECIFIC GRAVITy CORRECTION FACTORS FOR NATURAl GAS WARNING Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and ...
Page 51 - Connect; National Fuel
51 TABlE 7: MAXIMUM CAPACITy OF SChEDUlE 40 PIPE IN CFh* FOR NATURAl GAS PRESSURES OF 0.5 PSIG OR lESS Figure 7: Recommended Gas Piping TABlE 8: EqUIVAlENT lENGThS OF STANDARD PIPE FITTINGS & VAlVES B. Connect boiler gas valve to gas supply system. WARNING Failure to use proper thread compounds ...
Page 52 - Do not use matches, candles, open flames or
5 4. All above ground gas piping upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code , NFPA 70. C. Pressure test. The boiler and its gas connection must be leak tested...
Page 53 - A separate electrical circuit must be; once power is turned off.; Section of this manual.
5 VI. Electrical 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 ...
Page 55 - Figure 9: Internal Boiler Wiring ladder Diagram
55 Figure 9: Internal Boiler Wiring ladder Diagram NOTICE If an additional system limit is used, install in series with the auxiliary limit jumper shown in the drawing below.
Page 56 - System Controls and Wiring; for this type of system.; Set the thermostat heat anticipator to 0.12 amps.; “expansion” on the second, third or fourth R8889.
5 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 lin...
Page 62 - Combined Output
A. General Guidelines 1. Read and follow all venting, combustion air, water piping, gas piping and electrical instructions contained in this manual unless otherwise instructed in this section. 2. Consult Local Building Codes or National Fuel Gas Code, NFPA 54/ANSI Z222.3 for restrictions and instruc...
Page 65 - Figure : Operating Instructions
Page 66 - MV; TABlE 10: IGNITION MODUlE TERMINAl; Note; TABlE 11: yEllOW lED FlAME CODES
H. Operating Instructions . 1. Follow Operating Instructions to place boiler in operation. See Figure 36. 2. Electronic Ignition Modules with LED indicators. Table 10 cross-references the ignition module terminal designations to the ignition terminal Figure 7: lED locations Ignition Module Terminal ...
Page 67 - TABlE 1: GREEN lED STATUS CODES
7 Green LED Flash Code (X + Y) a Indicates Next System Action Recommended Service Action OFF No “Call for Heat” N/A None Flash Fast Startup - Flame sense calibration N/A None Heartbeat Normal operation N/A None 2 5 minute Retry Delay- Pilot flame not detected during trial for ignition Initiate new t...
Page 68 - Figure 8: Troubleshooting Guide; honeywell Electronic Ignition Troubleshooting Guide
8 Figure 8: Troubleshooting Guide honeywell Electronic Ignition Troubleshooting Guide
Page 70 - Failure to properly adjust gas input rate will result
70 TABlE 1: GAS FlOW RATE IN CUBIC FEET PER hOUR O. Check limit. 1. Adjust thermostat to highest setting.2. Observe temperature gauge. When temperature is indicated, adjust limit to setting below observed temperature. Main burners and pilot burner should extinguish, and blower should stop. 3. Adjust...
Page 71 - before attempting any disassembly or service.; the boiler back in service.
71 IX. Service A. General. Inspection and service should be conducted annually. Turn off electrical power and gas supply while conducting service or maintenance. Follow instructions TO TURN OFF GAS TO APPLIANCE. See Figure 36. B. Low water cutoff (if so equipped). Probe Type (Annual Service). Probe ...
Page 72 - Boiler Model
7 Figure 4: Silicone Tubing Assembly Figure 4: Blower Vent Connector Assembly 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 ...
Page 73 - Figure 44: Flue and Burner Cleanout, 1” Burner
Page 74 - Minimum Differential Pressure
74 Figure 45: Differential Pressure Measurement TABlE 15: DIFFERENTIAl PRESSURE SWITCh SETTINGS E. Main Burners and Firebox. 1. Vacuum firebox. Exercise care - do not damage base insulation. 2. Clean main burners. Brush top of burners with soft bristle brush. See Figure 44. Vacuum to remove any dirt...
Page 75 - ThIS PAGE lEFT INTENTIONAlly BlANk
Page 83 - . BASE ENClOSURE ASSEMBly
8 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 . BASE ENClOSURE ASSEMBly 3A Air Box Assembly 61807032 61807042 61807052 61807062 61807072 61807082 61807092 3B Air Box Door 71807034 71807044 71807054 71807064 71807074 71807084 71807094 3C Combustion Air Diffuse...
Page 87 - BURNER ASSEMBlIES
87 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 5. BURNER ASSEMBlIES 5A Gas Valve (Natural Gas), Honeywell VR8204P1171 81660282 N/A Gas Valve (Natural Gas), Honeywell VR8304P4496 N/A 81660283 Gas Valve (LP Gas), Honeywell VR8204C3015 81660146 N/A Gas Valve (LP...
Page 89 - . CONTROl PANEl ASSEMBly
89 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 . CONTROl PANEl ASSEMBly 6A Limit, Honeywell L4080D 100189-01 6B Transformer/Relay, Honeywell R8285D 80160155U 6C Ignition Module, Honeywell S8670E3003 100959-01 6D Blower Relay, Honeywell R8222U1006 80160096U 6E...
Page 92 - MISCEllANEOUS PARTS CARTON
9 Key No. Description [Quantity] Part Number SCG-3 SCG-4 SCG-5 SCG-6 SCG-7 SCG-8 SCG-9 8. MISCEllANEOUS PARTS CARTON 8A Water Manifold 80607001 8B Temperature/Pressure Gauge 8056169 8C Circulator Wiring Harness 6130701 8D Safety Relief Valve 81660363 8E Boiler Drain Valve 806603061 8F Vent Terminal ...
Page 93 - Warning; AVOID Breathing Fiber Particulates and Dust; Precautionary Measures
9 Important Product Safety Information Refractory Ceramic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contac...
Page 94 - SERVICE RECORD; DATE
Page 96 - Limited Warranty; FOR RESIDENTIAL CAST IRON WATER BOILERS
9 79 water boiler for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and hydronics industry standards. These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity, is subjected to unauthoriz...