Burnham FREEDOM FCM120 Installation, Operating And Service Instructions
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Burnham FREEDOM FCM120 Installation, Operating And Service Instructions

Condensing high efficiency direct vent gas - fired hot water boiler
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WARNING:
Improper installation, adjustment, alteration, service or maintenance can cause property damage,
injury, or loss of life. For assistance or additional information, consult a qualifi ed installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
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  • Page 1 Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualifi ed installer, service agency or the gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing. 101008-01-12/06 Model: FCM120 ™...

  • Page 2: Table Of Contents

    Product Description ... 2 Specifi cations ... 2 III. Before Installing ... 3 Locating The Boiler ... 3 Mounting The Boiler ... 7 Air For Ventilation ... 10 VII. Venting ... 11 A. Vent System Design ... 12 B. Removing An Existing Boiler From Common Chimney ... 20 C.

  • Page 3: Specifi Cations

    The FCM090 and FCM120 are aluminum gas fi red condensing boilers designed for use in forced hot water heating systems requiring supply water temperatures of 180°F or less. These boilers are designed for installation on a wall, however they may be fl oor mounted using an optional pedestal kit available from U.S. Boiler Company, Inc. This boiler may be vented vertically or horizontally with combustion air supplied from outdoors.

  • Page 4: Before Installing

    • For new radiant heating systems, refer to the radiant tubing manufacturer’s boiler sizing guidelines. • For systems including a Alliance™ indirect water heater, size the boiler to have either the DOE Heating Capacity required for the Alliance™ or the net rating required for the heating system, whichever results in the larger boiler.
  • Page 5 6) The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will contaminate combustion air. Avoid areas near chemical products containing chlorine, chloride based salts, chloro/ fl uorocarbons, paint removers, cleaning solvents and detergents. Figure 4.1: Clearances To Combustible Or Non-combustible Material...
  • Page 6 TABLE 4.2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION TYPE OF VENT PIPE PIPE DIRECTION 60/100mm VERTICAL OR CONCENTRIC VENT- HEAT FAB SAF-T VENT PROTECH FASNSEAL VERTICAL OR Z-FLEX Z-VENT III FLEX-L STAR-34 HEAT FAB SAF-T VENT PROTECH FASNSEAL HORIZONTAL OR VERTI- Z-FLEX Z-VENT III CAL WITH OFFSETS FLEX-L STAR-34...

  • Page 7: Mounting The Boiler

    This boiler weighs approximately 110 pounds: • Two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when fi lled with water. Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler.
  • Page 8 Figure 5.1 Wall Mounting Hole Locations...
  • Page 9 Figure 5.2 Boiler Mounting/Hardware...

  • Page 10: Air For Ventilation

    Example: A FCM120 and a water heater are to be installed in a room measuring 6 ft – 3 in x 7 ft with an 8 ft ceiling. The water heater has an input of 30000 BTU/hr: Total input in thousands of BTU/hr = (120000 BTU/hr + 30000 BTU/hr) / 1000 = 150 MBTU/hr Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft...
  • Page 11 Figure 6.1: Boiler Installed In A Confi ned Space, Ventilation Air From Inside...

  • Page 12: Venting

    FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH: * Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in Table 7.6 * Do not attempt to mix components from different approved vent systems.
  • Page 13 The Vent Option #1 column in Table 7.1 describes a horizontal direct vent system using 60/100mm concentric vent pipe. From this column, we see that a FCM120 may have a vent length of up to 18 ft. The 90 degree reducing elbow is not considered.
  • Page 14 CLASSIFICATION USED IN THIS MANUAL ILLUSTRATED IN FIGURE VENT PIPE STRUCTURE PENETRATION AIR INTAKE PIPE STRUCTURE PENETRATION VENT PIPE SIZE AIR INTAKE PIPE SIZE FCM090 FCM120 FCM090 FCM120 FCM090 FCM120 FCM090 FCM120 VENT TERMINAL AIR INTAKE TERMINAL VENT MATERIAL AIR INTAKE MATERIAL...
  • Page 15 Figure 7.2: Horizontal Concentric Venting (Vent Option 1) Figure 7.3: Horizontal Twin Pipe Venting (Vent Option 2)
  • Page 16 TABLE 7.4: U.S. BOILER CONCENTRIC VENT COMPONENTS (VENT OPTION 1) PART NO. DESCRIPTION 80/125 x 60/100mm 101005-01 REDUCING ELBOW 101006-01 TERMINAL SECTION 101007-01 WALL GROMMET 100994-01 39” STRAIGHT 100995-01 19 1/2” STRAIGHT 100996-01 90 DEGREE ELBOW 100997-01 45 DEGREE ELBOW TABLE 7.5: PERMISSIBLE STAINLESS STEEL VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS (VENT OPTIONS 2, 5) MANUFACTURER...
  • Page 17 Figure 7.6a: Location of Vent Terminal Relative to Windows, Doors, Grade Figure 7.6b: Location of Vent Terminal Relative to Meters and Forced Air Inlets Figure 7.6c: Positioning Vent Terminal Under Overhangs...
  • Page 18 TABLE 7.7: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH VENT FITTING 60/100mm 90 CONCENTRIC ELBOW 60/100mm 45 CONCENTRIC ELBOW 3” 90 ELBOW 3” 45 ELBOW 6) Permitted Terminals for Vertical Venting (Vent Option 5) - A straight termination is installed in the end of the vent pipe. Vent manufacturer part numbers for these screens are shown in Table 7.5.
  • Page 19 CLASSIFICATION USED IN THIS MANUAL ILLUSTRATED IN FIGURE VENT PIPE STRUCTURE PENETRATION AIR INTAKE PIPE STRUCTURE PENETRATION VENT PIPE SIZE AIR INTAKE PIPE SIZE FCM090 FCM120 FCM090 FCM120 FCM090 FCM120 FCM090 FCM120 VENT TERMINAL AIR INTAKE TERMINAL VENT MATERIAL AIR INTAKE MATERIAL...

  • Page 20: Removing An Existing Boiler From Common Chimney

    Figure 7.9: Vertical Twin Pipe Vent System (Vent Option 5) B. Removing an Existing Boiler From a Common Chimney Read this only if the FCM boiler is replacing an existing boiler that is being removed from a common chimney. This section does not apply to the installation of a FCM boiler. In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances.

  • Page 21: Assembly Of 60/100Mm Concentric Venting

    C. Assembly of U.S. Boiler 60/100mm Concentric Venting Failure to follow the instructions could result in fl ue gas leakage into the combustion air or indoor air, resulting in unsafe or unreliable operation • Do not lubricate concentric gaskets with anything other than water. •...
  • Page 22 Figure 7.10: Installation of Reducing Elbow on Concentric Boiler Collar Figure 7.11: Dimension “L”...
  • Page 23 6) Use locking bands provided to join adjacent sections of 39” pipe as well as fi ttings. The terminal section and the male end of the 19 1/2” section must be held to the adjoining pipe with at least one #10 x 1/2” sheet metal screw. Drill a 1/8 hole through both outer pipes to start this screw.
  • Page 24 Figure 7.14: Preparing Terminal Section for Installation in the Wall Figure 7.15: Attaching Terminal Section...

  • Page 25: Assembly Of Stainless Steel Venting

    Vent systems made by Heat Fab, Protech, and Z-Flex rely on gaskets for proper sealing. When these vent systems are used, take the following precautions: • Make sure that gasket is in position and undamaged in the female end of the pipe. •...
  • Page 26 3) Assembly of Flex-L-Intl. Star-34 Vent System: a) Star-34 General Notes: • Do not cut Star-34 vent components. • Support horizontal piping sections at intervals of 48” or less. • Vertical venting systems must be supported by at least one Star-34 Fire stop. An additional vertical support is required after any offset.
  • Page 27 4) Assembly of Z-Flex Z-Vent III: a) General Notes: • Non-expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw. File or sand the cut end smooth before assembling. Expanded ends may be cut to adapt the SVE series III to the vent collar.
  • Page 28 5) Assembly of Heat Fab Saf-T Vent EZ Seal: a) Saf-T Vent General Notes: • These instructions cover the installation of Saf-T Vent EZ Seal. Saf-T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. •...
  • Page 29 6) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of fl ue gas fl ow. •...

  • Page 30: Condensate Trap And Drain

    8) Installation of Vertical Exhaust Terminal - Use the terminal supplied by the vent system manufacturer shown in Table 7.5. Attach to the vent system, following the assembly instructions in this manual for the stainless vent system being used. 9) Assembly of the Air Intake System and Air Intake Terminals: a) Assemble the air intake system using either galvanized or PVC pipe.
  • Page 31 Figure 7.21: Condensate Piping Arrangement...

  • Page 32: Gas Piping

    Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fi re at the nameplate input at an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code.

  • Page 33: System Piping

    Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems (Pub. #200) published by the Hydronics Institute in Berkeley Heights, NJ. TABLE 9.1: FLOW REQUIREMENTS THROUGH BOILER BOILER MODEL FCM090 FCM120 IX System Piping A. General System Piping Precautions WARNING CAUTION B.
  • Page 34 15ft Straight Pipe + 6 Elbows x 2.75 + 2 Runs of Tees x 1.75 + 1 Swing Check x 7 + 2 valves x 0.6 = 43.2 equivalent feet straight pipe. From Table 9.5, we see that a Taco 0014 will pump 9 GPM through a FCM120 with 61 equivalent feet of pipe, so the Taco 0014 is OK.
  • Page 35 Equivalent Feet Straight Pipe. From Table 9.6, we see that smallest circulator which will pump at 8 GPM through a FCM120 with 52.95 equivalent feet and an indirect water heater pressure drop of 3 ft is a Taco 0014. Figure 9.2: Piping Method #1 - Heat Only...
  • Page 36 Figure 9.3: Piping Method #1 - Heat + Indirect Water Heater Figure 9.4a: Piping Method #1 - Secondary Loop Piping (Shaded)
  • Page 37 Figure 9.4b: Piping Method #1 - Indirect Water Heater Loop Piping (Shaded) Figure 9.4c: Modular Boiler Piping...
  • Page 38 (in NPT) FCM090 FCM090 FCM120 FCM120 FCM120 NOTE: 1) Use isolation relay between Taco 0013 and FCM - see Figure 10.3 TABLE 9.6: PIPE AND CIRCULATOR SIZING FOR INDIRECT WATER HEATER LOOP BOILER PIPE FLOW MODEL SIZE (in NPT) (GPM)
  • Page 39 TABLE 9.7: FITTING EQUIVALENT LENGTHS FITTING 90 ELBOW TURN IN TEE RUN OF TEE SWING CHECK GATE VALVE Method 2: Direct Connection to Heating System (Generally NOT Recommended) The FCM can be connected directly to the heating system as is done with conventional boilers (Figure 9.8). If this is done, the fl...

  • Page 40: Standard Piping Installation Requirements

    C: Standard Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping: 1) The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 2.1. The relief valve is set to open at 30 psi.

  • Page 41: Piping For Special Situations

    2) Circulator (Required) - Usually at least two circulators will be required to properly install a FCM Series boiler. See the previous section for information on sizing the circulators. 3) Expansion Tank (Required) - If this boiler is replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused.
  • Page 42 Figure 9.10: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 9.11: Chiller Piping...

  • Page 43: Wiring

    • Terminals 3 and 4 – “External Limit Control” connections • Terminals 5 and 6 – “Outdoor Reset Sensor” connections • Terminals 7 and 8 – “Domestic Indirect Water Heater” thermostat connections • Terminal 9 – “Flame Signal Reading” • Heat anticipator setting for the thermostat connection is 0.1 A when thermostat is connected directly to terminals 1 and 2.
  • Page 45 Figure 10.2: Ladder Diagram...
  • Page 46 Figure 10.3: Wiring of Isolation Relay for Control of Two Heating Circulators...

  • Page 47: Start-Up And Checkout

    SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE MET WITH THE GAS TRAIN ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TEST SPECIFIED IN Z21.13. Use the following procedure for initial start-up of the boiler: 1) If not already done, fl ush the system to remove sediment, fl ux, and traces of boiler additives. This should be done with the boiler isolated from the system.
  • Page 48 This boiler is equipped with an aluminum heat exchanger that can be seriously damaged by failure to follow the following guidelines: 1) Flush the system before connecting the boiler sediment, solder fl ux, and traces of old boiler additives. Even if the system is new, do not omit this step - new systems will contain solder fl...
  • Page 49 FCM Series Lighting and Operating Instructions...
  • Page 50 7) Start the boiler using the lighting instructions on page 49. After the boiler is powered up, it should go through the following sequence. Sequence Display U.125 or Blank 0.SWT (After call for heat from heating thermostat) A.SWT 5.SWT 1.SWT 2.SWT 3.SWT 8) Upon initial start-up, the gas train will be fi...
  • Page 51 At both high and low fi re, CO readings should be less than 75 PPM. Typical CO TABLE 11.3: TYPICAL CO Figure 11.2: Gas Valve Detail COMBUSTION READINGS RANGE Model Fuel FCM120 Natural Gas FCM120 Propane 10.5 readings are shown in Table 11.3.
  • Page 52 12) Test any external limits or other controls in accordance with the manufacturer’s instructions. 13) Verify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect water heater thermostat. Make sure that the appropriate circulators also start and stop in response to the thermostats.

  • Page 53: Operation

    1) The FCM boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including fl ame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the MCBA’s memory; one for space heating and one for domestic water production. If an outdoor temperature sensor is connected to the boiler, the space heating supply set point will automatically adjust downwards as the outdoor temperature increases.
  • Page 54 It is not the actual domestic hot water set point. The FCM is designed for use with a storage type indirect water heater such as the Alliance. The domestic water set point is controlled by the thermostat on the indirect water heater.
  • Page 56 30°F, the set point temperature for the supply water is 140°F. 5) An indirect water heater thermostat can be connected between terminals 7 and 8 on the terminal strip. When this thermostat closes, the central heating circulator will be turned off and the DHW circulator will be turned on.
  • Page 57 d) After the prepurge, the control module energizes the gas control valve and the spark for 4.5 seconds. If a fl ame is established and proved, the control allows the fl ame to stabilize for 5 seconds at the combustion fan ignition speed setting.

  • Page 58: Service And Maintenance

    WARRANTY DOES NOT COVER BOILER DAMAGE OR MALFUNCTION IF THE FOLLOWING STEPS ARE NOT PERFORMED AT THE INTERVALS SPECIFIED 1) Continuously: a. Keep the area around the boiler free from combustible materials, gasoline and other fl ammable vapors and liquids. b.
  • Page 59 d. Remove the ignition electrode and inspect it for oxides. Clean the oxides off the electrode with sandpaper. Inspect the ceramic insulator for cracks and replace the ignitor assembly if necessary. e. Remove the fan/gas valve assembly from the burner hood. Inspect for lint and dust. If signifi cant lint and dust are found, disassemble the fan/gas valve assembly to expose the swirlplate and fan inlet (see the exploded diagram in the parts list at the back of this manual).

  • Page 60: Troubleshooting

    Turn off power to boiler before replacing fuses or working on wiring. A. Troubleshooting problems where no error code is displayed: TABLE 14.1: NO ERROR CODE DISPLAYED CONDITION Display Blank, Fan off, LWCO lights off Display Panel Blank, Fan running Display reads “U.125”...
  • Page 61 B. Trouble shooting problems where a soft lockout code is displayed. When a soft lockout occurs, the boiler will shut down and the display will alternate between the number “9” and the letter “b” followed by a two digit service code. The boiler will automatically restart once the condition that caused the lockout is corrected.
  • Page 62 C. Trouble shooting problems where a hard lockout code is displayed. When a hard lockout occurs, the boiler will shut down and the display will fl ash the letter “E” followed by a two digit service code. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the RESET button on the display.

  • Page 63: Parts

    All FCM Series 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...
  • Page 65 100383-01 100384-01 100497-01 100385-01 100510-01 100509-01 100386-01 100387-01 100493-01 100506-01 100508-01 100507-01 100388-01 100389-01 100390-01 100391-01 100392-01 100393-01 100394-01 100395-01 FCM120 QUANTITY 100362-01 100487-01 100364-01 100542-01 100537-01 100536-01 100368-01 100453-01 100542-01 100371-01 100372-02 101049-01 100373-01 100374-01 100375-01 100365-01 100366-01 100520-01...
  • Page 67 100486-01 101020-01 101021-01 101022-01 101023-01 101024-01 101025-01 100462-01 101026-01 101027-01 101028-01 101029-01 100471-01 100466-01 100467-01 101030-01 100424-01 100474-01 100463-01 100469-01 FCM120 QUANTITY 100396-01 100397-01 100539-01 100398-01 100399-01 101010-01 101011-01 100429-01 101012-01 101013-01 101014-01 101015-01 101016-01 101017-01 100456-01 101018-01 101019-01 100486-01...
  • Page 71 101078-01 101079-01 101080-01 101081-01 101082-01 101083-01 101084-01 101085-01 101086-01 101087-01 101088-01 100540-01 101089-01 101090-01 101091-01 101092-01 101093-01 101094-01 101095-01 101096-01 FCM120 QUANTITY 100450-01 100452-01 100449-01 101031-01 101032-01 101033-01 101034-01 100468-01 101035-01 100423-01 101036-01 101037-01 101038-01 101039-01 101040-01 101041-01 101042-01 101043-01...
  • Page 75 NOTES...

  • Page 76: Special Requirements For Side-Wall Vented Appliances In The Commonwealth Of Massachusetts

    Appendix A: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above fi...
  • Page 77 the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the fl ue gases, but identifi es “special venting systems”, the following requirements shall be satisfi ed by the manufacturer: 1.
  • Page 78 NOTES...
  • Page 79 NOTES...

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