INSTALLATION AND SERVICE MANUAL SC SERIES GAS BOILERS FOR MODELS SC-35 TO SC-280 SEE REAR COVER FOR INDEX This manual must only be used by a qualified heating installer, service technician or gas supplier. See Section 3.11 for Installer’s Checklist See Section 4.3 for Service Checklist Manufactured by Allied Engineering Company Division of E-Z-Rect Manufacturing Ltd. Manufacturers of Gas and Electric Boilers, Stainless Steel Tanks, Heat Exchangers and Electric Boosters.
SC SERIES BOILERS DIMENSIONS AND SPECIFICATIONS MODEL NUMBER INPUT* OUTPUT DIM A DIM B SHIPPING WEIGHT MBH kW MBH kW In cm in cm lb kg SC-35 35 10.3 30.2 8.9 8.7 22.1 3 7.6 166 75 SC-70 70 20.5 60.5 17.7 11.7 29.7 3 7.6 198 90 SC-105 105 30.8 90.9 26.6 14.7 37.3 3 7.6 230 104 SC-140 140 41.0 121.3 35.5 17.7 44.9 3 7.6 262 119 SC-175 175 51.3 151.6 44.4 20.7 52.5 4 10.2 294 133 SC-210 210 61.6 182.2 53.4 23.7 60.1 4 10.
SC Series Boilers – Installation and Service Manual ABOUT OUR MANUALS Your Super Hot boiler has been provided with two manuals: • User's Information Manual - This manual is intended for the owner or user of the boiler and provides information on routine operation and maintenance, and emergency shutdown. • Installation and Service Manual - This manual must only be used by a qualified heating installer, service technician or gas supplier.
SC Series Boilers – Installation and Service Manual FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. A. This appliance does not have a pilot. It is • If you cannot reach your gas supplier, equipped with an ignition device which call the fire department. automatically lights the burner. Do not try C. Use only your hand to push in or turn the to light the burner by hand.
SC Series Boilers – Installation and Service Manual Installation Instructions 2.1 Section 2 RECEIVING INSPECT SHIPMENT FOR POSSIBLE DAMAGE. All goods are carefully manufactured, inspected, checked and packed by experienced workers. The manufacturer's responsibility ceases upon delivery of goods to the carrier in good condition. Any claims for damage and/or shortage in shipment or nondelivery must be filed immediately against the carrier by the consignee. Use care when receiving and unpacking the boiler.
SC Series Boilers – Installation and Service Manual • This boiler must be installed such that gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.). • Structure through which venting will pass must be free and clear for opening (i.e. no hidden conduit, telephone cables or other obstructions). 2.
SC Series Boilers – Installation and Service Manual These chemicals are especially commons near swimming pools, beauty shops, dry cleaning establishments, laundry areas, workshops, and garages. The warranty is void when failure is due to corrosion. 2.6 VENTING AND COMBUSTION AIR Definitions: A direct vent system operates so that all air for combustion is obtained from the outdoor atmosphere and all flue gases are discharged to the outdoor atmosphere.
SC Series Boilers – Installation and Service Manual The use of these manufacturers' venting systems for sidewall venting will require the vent terminal supplied by Allied Engineering Company. The vent terminal for vertical venting and these venting systems may be not supplied with this unit and should be obtained from the supplier of the venting system listed above. Condensate Trap All boilers with vertical venting installations require a condensate drain and drain trap.
SC Series Boilers – Installation and Service Manual Gas service meters: The vent terminal requires a clearance of 3 feet (0.9 m) and the air intake a clearance of 10 feet (3.0 m) from any gas service regulator vent outlet. Vents are prohibited above the gas meter assembly (not propane regulator vents) within 3 feet horizontally of the vertical center line of the regulator to a vertical distance of 15 feet (4.6 m).
SC Series Boilers – Installation and Service Manual Vent Installation The boiler must be vented to the outdoors. Do not install the vent into a common venting system and do not install a vent damper, or similar device to the venting system or the boiler. Vent connectors serving the boiler must not be connected into any portion of mechanical draft systems operating under positive pressure.
SC Series Boilers – Installation and Service Manual Figure 3 – Horizontal venting installed as a direct vent Figure 4 – Horizontal venting installed as a direct vent Figure 6 – Vertical venting installed as a direct vent Figure 5 – Horizontal venting installed as non-direct vent 11
SC Series Boilers – Installation and Service Manual Figure 7 – Vertical venting installed as a direct vent 2.7 Figure 8 – Vertical venting installed as non-direct vent WATER PIPING The water piping system of a boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle.
SC Series Boilers – Installation and Service Manual Super Hot SC series boilers are designed for use in closed loop systems and are not intended for open systems, as in heating pool water or systems where water is constantly replenished. Operating the boiler in an open system will result in premature failure of the heat exchanger. Super Hot boilers may be used to heat water in open systems indirectly by installing a heat exchanger, such as the Super Hot C-Coil, to separate open and closed systems.
SC Series Boilers – Installation and Service Manual Startup Instructions 3.1 Section 3 PRE-STARTUP a. Fill entire heating system with water and vent or purge air from system. Add water as needed to reach boiler operating pressure. Water should be of suitable quality. Do not use water with high hardness. b. Check that the venting condensate drain trap is filled with water. c. d. e. f. g. Check that the tubes tightly and correctly connect the air pressure switches with air chamber.
SC Series Boilers – Installation and Service Manual 6) 7) 8) 9) 10) b) will not restart the ignition sequence and the boiler will be able to be put back into operation only by removing the blockage and resetting the electrical power to the controller. Turn Gas Valve to ON. Main burner(s) should ignite. Check main burners and adjust the airflow, if necessary, as described in Section 3.3 and 3.5. Check for gas leaks of the joint between the gas valve outlet and manifold.
SC Series Boilers – Installation and Service Manual Chart 1: Operation Sequence for Spark and Hot Surface Ignition Control System.
SC Series Boilers – Installation and Service Manual 3.3 CHECK BURNER SYSTEM To maintain safe and efficient operation, examine the burner system regularly through the inspection window in the front of the boiler behind the door. Check condition of burner system It is possible for parts of the burners system to become plugged, cracked, eroded and/or dislodged resulting in unsafe operation. Check for lifting Flames should not lift excessively from the burner ports.
SC Series Boilers – Installation and Service Manual 3.5 AIR SWITCHES AND AIRFLOW ADJUSTMENT The boiler is equipped with two differential air pressure switches: 1. MINIMUM AIRFLOW (Red Light). The first air pressure switch closes and the indicator is on when there is enough combustion air supplied to the boiler for safe operation. The Minimum Airflow switch senses positive combustion air differential pressures (∆P) between the air chamber and burner venturi inlet.
SC Series Boilers – Installation and Service Manual Airflow Adjustment After the boiler and its venting system have been installed, use the following procedure to adjust the boiler to the proper airflow: a) The airflow adjustment can only be done correctly when the boiler is hot. b) Turn gas valve off. c) Turn the air adjustor screw located on the blower inlet clockwise to slide the air adjustor closed.
SC Series Boilers – Installation and Service Manual 3.6 GAS MANIFOLD PRESSURE These boilers are factory equipped for operation at altitudes ranging from 0 to 2,000 feet above sea level. The designated manifold pressures for sea level application are as shown in the table below. Model Natural Gas Propane All Models for 0 to 2,000 feet altitude 3.5” W.C. 9” W.C.
SC Series Boilers – Installation and Service Manual 3.7 CHECK INPUT & ORIFICES For safety, the input shown on rating plate must not be exceeded. Check with the following table that the orifice size and input rate shown on your boiler rating plate match your application, i.e. boiler model, fuel type, and altitude. To adjust manifold pressure, follow the procedure described in Section 3.6. If the derated input rating for high altitude requires a change in orifice size, contact the boiler manufacturer.
SC Series Boilers – Installation and Service Manual Adjustments to the input rate can be made by varying the manifold pressure. Normally it should be adjusted no more than 0.1 inch w.c. for natural gas or 0.4 inch w.c. for propane from the manifold pressure specified on the rating plate for that altitude application.
SC Series Boilers – Installation and Service Manual 3.11 INSTALLER'S CHECKLIST Reference Section The information printed on the boiler rating plate matches the application (i.e. altitude and fuel type). All applicable electrical codes have been met. 3.6 2.2, 2.12 Gas piping has been purged and checked for leaks with a soap solution, including the joint between the gas valve outlet and manifold when the boiler 2.2, 2.4, 3.9 is on. System is filled with water and all air has been purged.
SC Series Boilers – Installation and Service Manual Service & Maintenance Instructions 4.1 Section 4 SERVICE & MAINTENANCE INSTRUCTIONS WARNING Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. WARNING If any part of this boiler has been under water, inspect the boiler and replace any part of the control system and any gas control which has been under water.
SC Series Boilers – Installation and Service Manual 4.3 SERVICE CHECKLIST Reference Section Do not store anything against the boiler or allow dirt or debris to accumulate in the area immediately surrounding the boiler. The flow of supply and exhaust air must not be obstructed. Check air openings are not restricted and complies with applicable code(s). Adequate supply air is necessary for combustion, flue gas dilution and ventilation.
SC Series Boilers – Installation and Service Manual 4.4 CAUTION: WATER REPLENISHMENT Avoid unnecessary replenishment of system water. It can allow oxygen to enter the system and cause serious corrosion problems. As well, an excessive amount of minerals may be deposited in the heat exchanger. Do not draw water from the heating system for cleaning, flushing, etc.
SC Series Boilers – Installation and Service Manual Replacement Parts Section 6 NOTE: To supply the correct part it is important that you state the boiler model number, serial number and type of gas when applicable. Any part returned for replacement under standard company warranties must be properly tagged with Return Goods Authorization Form (R.G.A.), completely filled in with the boiler serial number, model number, etc., and shipped to the Company freight prepaid.
SC Series Boilers – Installation and Service Manual FIGURE 12 - GENERAL ASSEMBLY PARTS LIST 28
SC Series Boilers – Installation and Service Manual Wiring Diagrams 7.1 Section 7 Simplified Wiring Instructions IMPORTANT • Disconnect power source to boiler before wiring zone control board. • All wiring must comply with applicable codes, ordinances and regulations. • The non-replaceable fuse on the board will be blown if 240 Vac is connected to the board or if the 24 Vac system is even momentarily shorted out.
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SC Series Boilers – Installation and Service Manual Troubleshooting Guide Section 8 8.1 Possible Causes and Solutions Problem Boiler will not fire. Boiler goes on and off at frequent intervals. Boiler fires continuously. Rumbling and moaning sound in boiler. Gas odor. Flame flash back Possible Cause Solution • No power. • Check power switches and wiring. • No gas supply to boiler. • Check gas source and pressure. • Gas supply pipes are not purged of air. • Purge gas line.
SC Series Boilers – Installation and Service Manual Problem Main burner will not light Spark or hot surface proves but flame failure after trial for ignition. Burner starts but flame will not stay established. Boiler carbonizes (forms soot) quickly. Boiler overheats and system remains cold. Boiler and heating system overheat. Possible Cause Solution • High voltage wiring is loose, broken or grounded. Repair wiring. Ignition electrodes or H.S. are damaged. • Replace electrodes or igniter.
SC Series Boilers – Installation and Service Manual Fenwal Module Fault Conditions: LED Indication Steady on 1 flash 2 flashes 3 flashes Error Mode Internal control failure Air flow fault (hard lockout) Flame with no call for heat Ignition lockout (1 hour lockout) The LED will flash on for ¼ second, then off for ¼ second during a fault condition. The pause between fault codes is 3 seconds. Troubleshooting Guides: Symptom 1. Dead 2. Thermostat on – no blower 3.
SC Series Boilers – Installation and Service Manual NOTES Section 9 37
SC Series Boilers – Installation and Service Manual NOTES Section 9 38
SC Series Boilers – Installation and Service Manual NOTES Section 10 39
SC Series Boilers – Installation and Service Manual INDEX Section 10 Section Page Dimensions and Specifications – SC Series Boilers .................................................................................... 2 About Our Manuals ....................................................................................................................................... 3 1 Lighting Instructions..............................................................................................................
