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

Burnham FREEDOM 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 qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.
101008-01r2-7/07
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  • Page 1 ™ Warning: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing. 101008-01r2-7/07...

  • Page 2: Table Of Contents

    Table of Contents Product Description ................3 Specifications ..................3 III. Before Installing .................. 4 Locating The Boiler ................4 Mounting The Boiler ................7 Air For Ventilation ................10 VII. Venting ....................12 Vent System Design ..............12 Removing An Existing Boiler From Common Chimney ....20 C.

  • Page 3: Product Description

    I Product Description The FCM070, 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. This boiler is not designed for use in gravity hot water systems or systems containing signifi cant amounts of dissolved oxygen. II Specifi cations Figure 2.1: General Confi guration TablE 2.2: sPECiFiCaTiOns D.O.E. APPROX. MAXIMUM MINIMUM IBR NET WATER NO. OF HEATING NET INPUT INPUT RATING AFUE (%) VOLUME MODEL* SECTIONS CAPACITY WEIGHT...

  • Page 4: Before Installing

    III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1. • W here required by the authority having jurisdiction, this installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1). 2) FCM boilers utilize aluminum heat exchangers constructed, tested, and stamped in accordance with ASME Boiler and Pressure Vessel Code Case 2382-2. Some jurisdictions which require ASME boiler construction do not recognize this Code Case and may not approve the installation of an aluminum boiler. Consult the authority having jurisdiction before installing this boiler. 3) Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with Section VII. 4) Make sure that the boiler is correctly sized: • For heating systems employing convection radiation (baseboard or radiators), use an industry accepted sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkely Heights, NJ. • 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. • For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instructions for boiler output requirements. 5) Make sure that the boiler received is configured for the correct gas (natural or LP). 6) Make sure that the boiler is configured for use at the altitude at which it is to be installed. nOTiCE This product must be installed by a licensed plumber or gas fitter when installed within the Commonwealth of Massachusetts.
  • 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/ fluorocarbons, paint removers, cleaning solvents and detergents. Figure .1: Clearances To Combustible Or non-combustible Material...
  • Page 6 TablE .2: ClEaranCEs FrOM VEnT PiPing TO COMbusTiblE COnsTruCTiOn MINIMUM CLEARANCE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE TO COMBUSTIBLE MATERIAL 80/125 and 60/100mm VERTICAL OR ENCLOSED ON ALL FOUR SIDES 0” CONCENTRIC VENTING HORIZONTAL HEAT FAB SAF-T VENT AT LEAST ONE SIDE OPEN, PROTECH FASNSEAL VERTICAL OR 1”...

  • Page 7: Mounting The Boiler

    V Mounting The Boiler CauTiOn 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.
  • Page 8 Figure .1 Wall Mounting Hole locations...
  • Page 9 Figure 5.2 Boiler Mounting/Hardware...

  • Page 10: Air For Ventilation

    VI Air for Ventilation Warning OuTDOOr COMbusTiOn air MusT bE PiPED TO THE air inTaKE. nEVEr PiPE COMbusTiOn air FrOM arEas COnTaining COnTaMinaTEs suCH as sWiMMing POOls anD launDrY rOOM EXHausT VEnTs. COnTaMinaTED COMbusTiOn air Will DaMagE THE bOilEr anD MaY CausE PrOPErTY DaMagE, PErsOnal inJurY Or lOss OF liFE.
  • Page 11 Figure 6.1: Boiler Installed In A Confined Space, Ventilation Air From Inside...

  • Page 12: Venting

    VII Venting Warning 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 Tables 7.a or 7.b.
  • Page 13 2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option selected and the boiler size. See Table 7.1 or 7.9 for the maximum vent length. In horizontal vent systems, the lengths shown in Table 7.1 are in addition to the first standard elbow on top of the boiler. For vertical vent systems, the maximum vertical vent lengths shown in Table 7.9 are in addition to two elbows. If more elbows are desired, the maximum allowable vent length must be reduced by the amount shown in Table 7.8 for each additional elbow used. Termination fittings are never counted, although the length of the concentric terminal section, included with the boiler, is counted. Example: A 60/100mm concentric vent system is planned for a horizontally vented FCM120 which has the following components: 80/125 x 60/100mm Reducing Elbow (supplied with the boiler) 5 ft Straight Pipe. 90 elbow 1 ½ ft Straight Pipe 45 Elbow Uncut Terminal Section (supplied with the boiler) 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. The length of the terminal section (not including the plastic terminal itself) is approximately 22 1/2” (1.9 ft) installed. From Table 7.8, we see that the equivalent length of the 60/100mm elbow is 4.5 ft and that the equivalent length of the 45 degree elbow is 4 ft. The total equivalent length of the planned venting system is therefore: 5 ft (Straight ) + 4.5 ft (90 Elbow) + 1.5 ft (Straight ) + 4 ft (45 Elbow) + 1.9 ft (Uncut Terminal Section) = 16.9 ft. Since Table 7.1 shows a maximum allowable vent length of 18 ft, the planned vent system length is acceptable. 3) Minimum Vent and Air Intake Lengths - Observe the minimum vent lengths shown in tables 7.1 and 7.9. 4) Permitted Terminals for Horizontal Venting: • Vent Option 1 - The concentric 60/100mm concentric vent terminal is supplied with the boiler as part of the standard vent system. • Vent Option 2 - The exhaust terminal is U.S. Boiler part 8110701. The air intake fitting is a 90 degree elbow with a rodent screen supplied by the installer. This elbow is made out of the same material as the rest of the air inlet system (either galvanized or PVC) and is installed as shown in Figure 7.3 • Vent Option 3 - Two terminals are permitted: a. 80/125mm Concentric Vent Terminal (U.S. Boiler part 101494-01).
  • Page 14 Horizontal Terminal Clearance Requirements (Continued): • Vent terminal must be at least 6 feet from an inside corner. • Under certain conditions, water in the flue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by flue gas condensate, they should be moved or protected. • If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph. • Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near swimming pools. See Section IV for more information on possible contaminates. TablE 7.1: suMMarY OF HOriZOnTal VEnTing OPTiOns VENT OPTION # CLASSIFICATION USED IN THIS HORIZONTAL HORIZONTAL HORIZONTAL MANUAL CONCENTRIC TWIN PIPE CONCENTRIC ILLUSTRATED IN FIGURE 7.2 VENT PIPE PENETRATION WALL WALL WALL THROUGH STRUCTURE AIR INTAKE PIPE PENETRATION WALL WALL WALL THROUGH STRUCTURE VENT PIPE SIZE 3”...
  • Page 15 Figure 7.2: Horizontal Concentric Venting (Vent Options 1, 3) Figure 7.3: Horizontal Twin Pipe Venting (Vent Option 2)
  • Page 16 TablE 7.a: u.s. bOilEr COnCEnTriC 0/100 VEnT COMPOnEnTs (VEnT OPTiOn 1) USED ON PART NO. DESCRIPTION SIZE COMMENTS VENT OPTION # 80/125 x 60/100mm 80/125 x 101005-01 INCLUDED WITH STANDARD BOILER REDUCING ELBOW 60/100mm 101006-01 TERMINAL SECTION 60/100mm INCLUDED WITH STANDARD BOILER 101007-01 WALL GROMMET 60/100mm INCLUDED WITH STANDARD BOILER 101141-01 39” STRAIGHT 60/100mm OPTIONAL - MAY NOT BE CUT 101140-01 78" STRAIGHT 60/100mm OPTIONAL - MAY NOT BE CUT 101142-01 19-1/2” STRAIGHT 60/100mm...
  • Page 17 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. The air inlet terminal consists of a 180 degree elbow (or two 90 degree elbows) with a rodent screen as shown in Figure 7.10 • Vent Option 6 - Use U.S. Boiler part 101495-01 with the appropriate flashing (see Table 7.4b). 7) Vertical Vent Terminal Locations (Vent Options 5, 6) - Observe the following limitations on the location of all vertical vent terminals (see Figures 7.10 and 7.11): • The top of the vent pipe must be at least 2 feet above any object located within 10 feet. • For Vent Option #5, the vertical distance between top of the vent and air inlet terminal openings must be at least 12". • The bottom of the air inlet terminal must be at least 12” above the normal snow accumulation that can be expected on the roof. The terminal used in Vent Option #6 has a fixed distance above the storm collar of 19". If a greater distance is needed to provide the clearance above the snow line, build a chase on the roof and mount the vertical terminal on top of the chase. • For Vent Option #5, the air intake terminal must be located on the roof and must be no further than 24" horizontally from the exhaust pipe. 8) Wall thimbles – Wall thimbles are required where single wall vent pipe passes through combustible walls with less than the required clearance shown in Table 4.2 or as required by local codes. Stainless vent manufacturer’s wall thimble part numbers are shown in Table 7.5. Note that concentric vent has a "zero" clearance to combustibles and therefore does not require the use of wall thimbles. TablE 7.: PErMissiblE sTainlEss sTEEl VEnT sYsTEMs anD PrinCiPlE VEnT COMPOnEnTs (VEnT OPTiOns 2, ) MANUFACTURER VENT SYSTEM SIZE...
  • Page 18 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 19 9) Pitch of Horizontal Piping - Pitch all horizontal piping so that any condensate which forms in the piping will run towards the boiler: • Pitch U.S. Boiler horizontal concentric venting 5/8” per foot • Pitch Stainless steel venting 1/4” per foot. 10) Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported: • Support U.S. Boiler concentric venting near the female end of each straight section of pipe. Exception: Vertical runs of concentric pipe in an unused chimney (Figure 7.36) need only be supported at the terminal and at the base of the run. • Support stainless steel venting as called for by the vent manufacturer’s instructions. Figure 7.7: Snorkel Terminal Configuration...
  • Page 20 TablE 7.8: VEnT/ air inTaKE FiTTing EQuiValEnT lEngTH VENT FITTING EQUIVALENT LENGTH (ft) 60/100mm 90° CONCENTRIC ELBOW 60/100mm 45° CONCENTRIC ELBOW 80/125mm 90° CONCENTRIC ELBOW 80/125mm 90° SWEEP CONCENTRIC ELBOW 80/125mm 45° CONCENTRIC ELBOW 80/125mm 90° CONCENTRIC SUPPORT ELBOW 3” SINGLE WALL 90° ELBOW 3” SINGLE WALL 45° ELBOW TablE 7.9: suMMarY OF VErTiCal VEnTing OPTiOns VENT OPTION # CLASSIFICATION USED IN THIS VERTICAL VERTICAL MANUAL TWIN PIPE CONCENTRIC ILLUSTRATED IN FIGURE 7.10 7.11 VENT PIPE PENETRATION...
  • Page 21 Figure 7.10: Vertical Twin Pipe Vent System (Vent Option 5) Figure 7.11: Vertical Concentric Vent system (Vent Option )

  • Page 22: Removing An Existing Boiler From Common Chimney

    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. 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. (a) Seal any unused openings in the common venting system. (b) V isually 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. (c) I nsofar as practical, close all building doors and windows and all doors between the space in which all 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. (d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so the appliance will operate continuously. (e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe. (f) 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 appliances to their previous condition of use. (g) Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1. Warning nEVEr COMMOn VEnT a FCM bOilEr WiTH OTHEr aPPlianCEs.

  • Page 23: Assembly Of U.s. Boiler 60/100Mm Concentric Venting

    C. Assembly of U.S. Boiler 60/100mm Concentric Venting (IMPORTANT - Skip to Section D for 80/125mm Concentric Vent Assembly) Warning Failure to follow the instructions could result in flue gas leakage into the combustion air or indoor air, resulting in unsafe or unreliable operation •...
  • Page 24 Figure 7.20: Installation of Reducing Elbow on Concentric Boiler Collar Figure 7.21: Dimension “l”...
  • Page 25 6) Use locking bands provided to join adjacent sections of non-cuttable pipe as well as fittings. The male end of the terminal section and other cuttable sections must be held to the female end of the adjoining pipe with at least three #10 x 1/2” sheet metal screws. Drill a 1/8" hole through both outer pipes to start this screw. Use a drill stop or other means to ensure that the drill bit does penetrate more than 3/8” into the outer pipe. Do not use a sheet metal screw longer than 1/2”. 7) The only straight pipe that can be cut is the terminal section and the 19-1/2” section (P/N 101142-01) and the 80/125 straight riser (P/N 101163-01). To cut this pipe: a) Cut pipe from the male end. After marking the desired length of the outer pipe, remove the plastic inner pipe by pulling it out from the female end.
  • Page 26 Figure 7.2: Preparing 0/100mm Terminal section for installation in the Wall Figure 7.2: attaching 0/100mm Terminal section...

  • Page 27: Assembly Of U.s. Boiler 80/125Mm Concentric Venting

    D. Assembly of U.S. Boiler 80/125mm Concentric Venting (IMPORTANT - See Section C for 60/100mm Concentric Vent Assembly) Warning Failure to follow the instructions could result in flue gas leakage into the combustion air or indoor air, resulting in unsafe or unreliable operation •...
  • Page 28 To cut the straight sections listed above refer to Figure 7.31 and the following instructions: a) Determine the required length of the outer pipe. When doing this allow an additional 1" of length for insertion into the female end of the adjoining pipe. Mark the cut line on the outer pipe. b) Remove the plastic inner pipe by pulling it out from the female end. c) Cut the OUTER PIPE ONLY at the point marked in Step (a) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr the cut end with a file or emery cloth. d) Make an insertion mark 1" from the male end of the outer pipe. e) Cut the plastic inner pipe so that it will protrude 3/8" beyond the male end of the outer pipe when reinstalled in the outer pipe. Use a fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square. Deburr the cut edge of the plastic pipe with a file, razor blade, or fine sandpaper. f) Reinstall the inner pipe. Figure 7.31: Cutting straight Pipe...
  • Page 29 3) Joining Pipe - a) Start assembly of the vent system at the boiler. Lubricate the brown gasket in the boiler vent collar with a few drops of water. b) Push the male end of the first fitting into the boiler collar until it bottoms out. The male end of cuttable sections should go 1” into the collar until the insertion mark (made in Step 2d above) is covered. On other fittings, the bead on the male pipe will be bottom out on the collar (Figure 7.32b). c) The male end of cuttable fittings must be held to the collar with three #10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start this screw. Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe. Do not use a sheet metal screw longer than 1/2” (Figure 7.32a). d) Use locking bands (provided with all fittings) to secure non-cuttable pipe, as well as fittings, to the boiler collar (Figure 7.32b).
  • Page 30 4) 80/125mm Horizontal Terminal Installation - a) Cut a 5-1/2” diameter hole through the exterior wall at the planned location of the horizontal terminal. b) Measure distance “L” from the outside surface of the exterior wall to the end of the last fitting as shown in Figure 7.33a. c) Add 1-1/4” to distance “L”. Carefully mark this length on the pipe as shown in Figure 7.33b. d) Remove the plastic inner pipe from the terminal, by gently pulling on it from the male end. Set aside. e) Cut the outer pipe only at the point marked in Step (c) using aviation shears, a hacksaw, or an abrasive wheel cutter. Be careful to cut the pipe square. De-burr the cut end with a file or emory cloth. f) Reinstall the plastic inner pipe in the terminal, making sure that the female end of this pipe is completely bottomed out over the aluminum male connection visible behind the air intake grill. Place a mark on the plastic inner pipe 3/8” beyond the end of the outer pipe (Figure 7.33c). Use a fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square (if necessary, the plastic pipe can be removed from the terminal again for cutting). De- burr the cut edge of the plastic pipe with a file, razor blade, or fine sandpaper. g) Make a mark on the terminal section 1” from the cut end of the outer pipe as shown in Figure 7.33c. h) Slip the terminal section through the wall from the outside. Pass the terminal through the inner wall plate and push into the last section of vent pipe until the mark made in Step (h) is not longer visible (Figure 7.33d). Secure the terminal to the last piece of pipe with three #10 x 1/2” sheet metal screws. Drill a 1/8 hole through both outer pipes to start these screws. Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe.
  • Page 31 Figure 7.33c: Cutting Inner Pipe of 80/125mm Horizontal Terminal Figure 7.33d: Completing 80/125mm Horizontal Terminal Installation...
  • Page 32 5) Snorkel Terminal Installation - The Snorkel Kit (P/N 101544-01) consists of the following (Also see Figure 7.34): Key No. Part No. Description 101620-01 Support Elbow iMPOrTanT 101621-01 Lower Wall Bracket The Terminal Elbow and Wall 101622-01 Air Intake Section Penetration Section included in 101623-01 Wall Bracket the snorkel kit have gaskets in the female end of the outer pipe. These 101624-01 Terminal Elbow gaskets prevent infi ltration of rain...
  • Page 33 d) Complete the vent system inside the structure. The support elbow sits on the M10 x 35 screw as shown in Figure 7.34. Cut the Wall Penetration Section to the length required to connect the interior vent system to the Support Elbow following the instructions on Page 27. e) Remove the Support Elbow from the Lower Support Bracket and attach it to the Wall Penetration Section. Slip this assembly through the Lower Support Bracket. Connect to the interior vent system. f) Slide an Outer Joint Gasket over the male end of the Air Intake Section with the tapered edge of the gasket pointing up. Attach the Air Intake Section to the Support Elbow. If necessary, the Air Intake Section can be shortened by cutting the male end as described on page 27. After attaching the Air Intake Section to the Support Elbow, slide the Outer Joint Gasket down over the joint between the two fi ttings to prevent rain infi ltration. g) Attach the Wall bracket to the wall 0”-6” from the bottom edge of the intake bell (Figure 7.34). Use 1/4” screws (not provided) to mount this bracket. h) Slide the remaining Outer Joint Gasket over the male end of the Terminal Elbow. Attach the Terminal Elbow to the Air Intake Section, pointing it away from the wall. Secure the Terminal Elbow to the Air Intake section with a single #10 x 1/2” sheet metal screw (Figure 7.34). Drill a 1/8 hole through both outer pipes to start this screw. Use a drill stop or other means to ensure that the drill bit does not penetrate more than 3/8” into the outer pipe. Do not use a sheet metal screw longer than 1/2”. Slide the Outer Joint Gasket down over the joint between the Terminal Elbow and the Air Intake Section to prevent rain infi ltration.
  • Page 34 Figure 7.3b: Cutting Vertical Terminal Figure 7.3c: Completing Vertical Terminal installation...
  • Page 35 7) Chimney Chase Installation - A vertical 80/125mm vent system can be installed in an unused masonry chimney. This installation is similar to other vertical installations with the following exceptions (Also see Figure 7.36): a) The chimney chase elbow kit (P/N 101492-01) is used at the base of the chimney. This kit consists of a support elbow and a mounting bracket. Slip the elbow over the M10 x 35 screw in the support bracket. Determine the desired vertical location of the support elbow in the chimney and mark the location of the pin on the back of the support bracket on the back wall of the chimney. Drill a 7/16”dia x 2-1/2” deep hole at this location to support the back of the bracket. The front of the elbow mounting bracket is supported by the bottom of the opening into the chimney or by an installer supplied bracket. b) Construct a weather-tight flat roof to cover the top of the old chimney. Install the vertical terminal through this roof using the flat roof flashing. WARNING • Do not attempt to construct a vertical vent system inside a chimney that is used to vent a fireplace or other appliances. • Do not attempt to construct a vertical vent system inside a chimney flue adjacent to another flue used by a fireplace or other appliances. Figure 7.3: Chimney Chase installation...

  • Page 36: Assembly Of Stainless Steel Venting

    E. Assembly of Stainless Steel Venting CauTiOn 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 37 3) Assembly of Metal-Fab Corr/Guard Vent System: a) Corr/Guard General Notes: • Do not cut Corr/Guard vent components. • Refer to Corr/Guard installation instructions for proper methods of support. • Orient Corr/Guard components so that the males ends of all fittings point in the direction of the boiler. b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the FCM vent collar. Bend the three hose clamp tabs on this collar outward slightly. c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Remove dirt, grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly. d) On the male end of the pipe, apply a ¼” wide bead of silicone approximately ½” from the end of the pipe (see Figure 7.47). e) Insert the male end of the pipe into the boiler vent collar until it bottoms out. f) Apply an additional bead of silicone over the outside of the joint and smooth out. g) Replace and tighten the clamp on the vent collar. h) Assemble remaining Corr/Guard components in accordance with the Corr/Guard installation instructions. i) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler. Figure 7.7: Corr/guard Connection to Vent Collar...
  • Page 38 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. See the following instructions. • Support horizontal piping sections at intervals of 48” or less. • Vertical venting systems must be supported by at least one Z-Flex fire stop. An additional vertical support is required after any offset and as required by the Z-Vent III installation instructions. b) Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the FCM vent collar. Bend the three hose clamp tabs on this collar outward slightly. c) Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Remove dirt, grease, and moisture from the surfaces to be sealed. Dry surfaces or allow to dry thoroughly. d) On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½ inch from the male end of the pipe. Apply ¼” beads of silicone along both sides of the longitudinal seam (Figure 7.48). e) Insert the male end of the pipe into the boiler vent collar until it bottoms out. f) A pply an additional bead of silicone over the outside of the joint and smooth out. g) Replace and tighten the clamp on the vent collar. h) The female end of each Z-Vent III component has a silicone sealing gasket. Examine all vent components to insure that the gasket integrity has remained during shipping. Gaskets must be in the proper position or flue gas could leak resulting in carbon monoxide poisoning. i) Align the second piece of pipe with the first and push them together as far as they will go, but not less than 1-3/4”. j) Tighten gear clamp to a minimum torque of 40 in-lbs and a maximum of 50 in-lbs. k) R epeat Steps (h) – (j) for the remaining Z-Vent III components. l) In horizontal vent systems, a locking band or gear clamp must be used at either side of the wall penetration to prevent shifting of the vent system in and out of the wall. This applies to both combustible and non-combustible walls. n) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler. FigurE 7.8: Z-VEnT iii COnnECTiOn TO VEnT COllar...
  • Page 39 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. • In general, Saf-T Vent pipe sections may not be cut. Exceptions to this are the Saf-T Vent slip connector and connections to the boiler vent collar. In these cases, use a sharp pair of aviation snips, an abrasive cut-off, or a plasma cutter. See the Saf-T Vent instructions for information on cutting the slip connector. • Orient Saf-T Vent components so that the arrows on the piping labels are in the direction of flue gas flow. • Support horizontal piping sections at intervals of 6 feet or less. • Vertical venting systems must be supported by at least one Heat Fab support. An additional vertical support is required after any offset. b) Connection to Boiler – Start assembly of the vent system at the boiler. Remove the hose clamp shipped on the FCM vent collar. Bend the three hose clamp tabs on this collar outward slightly. Cut the “male spigot” off of the first piece of pipe (Figure 7.49). If necessary, crimp the cut end of the pipe so that it can be inserted at least 1” into the collar. Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler with an alcohol pad. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ½ inch from the male end of the pipe. Also apply a ¼” bead of silicone along the first 2½” of the longitudinal weld. Insert the male end of the pipe into the boiler vent collar until it bottoms out. Apply an additional bead of silicone over the outside of the joint and smooth out (Figure 7.49). Replace and tighten the clamp on the vent collar. c) Assembly of Saf-T Vent EZ Seal Vent Components - Clean the male end of the next piece of pipe with an alcohol pad and make sure that it is free of burrs. Check the female end of the first piece of pipe to make sure that the gasket is in place and is undamaged. Using a slight twisting motion, insert the male end of the second fitting into the female end of the first fitting, taking care not to dislodge or cut the factory gasket. In extremely arid conditions, it may be easier to assemble these fittings if the gasket is moistened with water prior to assembly. Bend the locking tabs over the locking ring on the adjacent piece of pipe. Repeat these steps for the remaining Saf-T-Vent components. FigurE 7.9: saF-T VEnT EZ sEal COnnECTiOn TO VEnT COllar...
  • Page 40 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 flue gas flow. • Support horizontal piping sections at intervals of 6 feet or less. • Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is required after any offset. b) Remove the hose clamp shipped on the FCM vent collar. Bend the three hose clamp tabs on this collar outward slightly. Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler. Remove dirt, grease, and moisture from the surfaces to be sealed. On the male end of the pipe, apply a ¼” wide bead of high temperature silicone approximately ¼" from the male end of the pipe. Insert the male end of the pipe into the boiler vent collar until it bottoms out. Apply an additional bead of silicone over the outside of the joint and the seams on the vent collar and smooth out (Figure 7.50). Replace and tighten the clamp on the vent collar. c) All other joints in the FasNSeal venting system rely on a gasket in the female end of the pipe for a proper seal. d) Align the longitudinal seam of both pipes. Insert the male end of the second pipe into the female end of the first pipe until the bead on the male end contacts the flare on the female end. e) Tighten the locking band with a nut driver. f) Repeat (d) and (e) for the remaining FasNSeal components. g) Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler. FigurE 7.0: FasnsEal COnnECTiOn TO VEnT COllar 7) Installation of Horizontal Exhaust Terminal: a) When stainless steel venting is used, use U.S. Boiler stainless exhaust terminal P/N 8110701. The outer edge of this terminal must be between 6 and 12 inches from the surface of the wall. The joint between the terminal and the last piece of pipe must be outside of the building.

  • Page 41: 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. b) If PVC piping is used, use PVC cement to assemble the PVC intake system components. c) If galvanized piping is used, use at least two sheet metal screws per joint. Seal the outside of all joints. d) 3” galvanized smoke pipe will fit inside the inlet collar on the boiler. Depending upon the exact OD of the pipe used, it may be necessary to crimp this pipe. Secure with a single #10 sheet metal screw through the hole in the inlet collar and seal the outside of the joint with silicone. If PVC is used for the intake system, use a short piece of 3” galvanized pipe to connect the PVC to the boiler. Silicone the outside of the joint between the PVC and galvanized pipe. e) Horizontal intake terminal is a 90 degree elbow pointing down. Elbow should protrude the same distance from the wall as the exhaust terminal. f) Vertical air intake terminal consists of a 180 degree bend (composed of two 90 degree elbows) as shown in Figure 7.10. g) Install a rodent screen (not supplied) in the inlet terminal. Use a screen having 1/2” (2 x 2) or larger mesh. F. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system collects in the sump under the heat exchanger and leaves the boiler through the condensate trap. This trap allows condensate to drain from the sump while retaining flue gases in the boiler. The trap is supplied loose and must be installed as shown in Figure 7.51. A length of drain hose is supplied with the boiler and is connected to the trap as shown in Figure 7.51. Note the following when disposing of the condensate: a) If the condensate drain line must be extended, construct the extension from PVC or CPVC pipe. Insert the hose provided with the boiler into the end of the extension as shown in Figure 7.51. b) Condensate is slightly acidic. Do not use metallic pipe or fittings in the condensate drain line. Do not route the drain line through areas that could be damaged by leaking condensate. c) Some jurisdictions may require that the condensate be neutralized before being disposed of. Dispose of condensate in accordance with local codes. d) Do not route, or terminate, the condensate drain line in areas subjected to freezing temperatures. e) If the point of condensate disposal is above the trap, it will be necessary to use a condensate pump to move the condensate to the drain. In such cases, select a condensate pump that is approved for use with condensing furnaces. If overflow from this pump would result in property damage, select a pump with an overflow switch and use this switch to shut down the boiler. Alternatively, if heat is a necessity, use the overflow switch to trigger an alarm.
  • Page 42 FigurE 7.1: COnDEnsaTE PiPing arrangEMEnT...

  • Page 43: Gas Piping

    VIII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire 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. Figure 8.1 shows typical gas piping connection to the FCM boiler. A sediment trap must be installed upstream of all gas controls. Install the factory provided manual shut-off valve outside the jacket with a ground joint union as shown. The boiler and its gas connection must be leak tested before placing the boiler in operation. When doing this, the boiler and its individual shut-off must be disconnected from the rest of the system during any pressure testing of that system at pressures in excess of ½ psi. When pressure testing the gas system at pressures of ½ psi or less, isolate the boiler from the gas supply system by closing its individual manual shut-off valve. Figure 8.1: gas Connection To boiler...

  • Page 44: System Piping

    IX System Piping A. General System Piping Precautions Warning insTall bOilEr sO THaT THE gas igniTiOn sYsTEM COMPOnEnTs arE PrOTECTED FrOM WaTEr (DriPPing, sPraYing, rain, ETC) During aPPlianCE OPEraTiOn anD sErViCE (CirCulaTOr rEPlaCEMEnT, ETC). CauTiOn THE HEaT EXCHangEr usED in THE FCM is MaDE FrOM a sPECial aluMinuM allOY. FailurE TO TaKE THE FOllOWing PrECauTiOns COulD rEsulT in sEVErE bOilEr DaMagE.
  • Page 45 Method 1: Primary/Secondary Piping This method can be used in heat-only applications as shown in Figure 9.2 or with an indirect water heater as shown in Figure 9.3. This method relies on primary/secondary pumping to ensure that the required flow is always maintained through the boiler. In this system, the flow rate through the boiler is completely independent of the flow rate through the heating system. Use the following guidelines to ensure that the boiler will have the required flow shown in Table 9.1 regardless of the flow in the heating system. 1) Primary Loop Piping - Size the primary circulator and piping to obtain the design flow rate through the heating system as you would on any other heating system. All piping between the expansion tank and secondary connection tees must be at least as large as that shown in Table 9.5, column (a). In order to keep the flow rates in the primary and secondary loops independent of each other, provide at least 8 diameters of straight pipe upstream of the first secondary tee and 4 diameters downstream of the second secondary tee. Keep the distance between the expansion tank and the first secondary tee as short as practical. 2) Secondary Loop (“Boiler Loop”) Piping – All piping must be the size shown for the boiler in Table 9.5, column (a). To size the circulator: a) Select one of the boiler water flow rates shown in Table 9.5, column (b) for the boiler being installed. When selecting the required boiler flow rate, keep in mind that if the flow rate in the primary loop exceeds the flow rate through the boiler, it will not be possible to obtain a 180°F supply temperature in the primary loop. This is because the supply water exiting the boiler will be mixed with cooler system return water before entering the radiation. b) Count all fittings in the planned secondary loop (the secondary loop consists of the shaded piping in Figure 9.4a). In doing so, do not count the secondary connection tees, unions, or the fittings supplied with the boiler (these have already been accounted for). c) U sing Table 9.7, find the equivalent lengths of all fittings in the secondary loop. Total these equivalent lengths and add them to the total length of planned straight pipe in the secondary loop. The result is the total equivalent length of the secondary loop. d) U sing Table 9.5, find the boiler size being installed and select a boiler secondary circulator that shows a “maximum equivalent length” (column e) in excess of the total equivalent length calculated in Step 2c. 3) Indirect Water Heater Loop Piping (If Indirect Water Heater is Used) – All piping must be the size shown in Table 9.6, column (a). If the indirect water heater connections are smaller than the pipe size called for in column (a), reduce the pipe size at the indirect water heater connections. To size the circulator: a) C ount all fittings in the planned Indirect Water Heater Loop (the indirect water heater loop consists of the...
  • Page 46 Example (contd.) Total fittings in Indirect Water Heater Loop: 5 90 Elbows 2 Turns in Tees 1 Swing Check 2 Isolation Valves Calculate total equivalent length from Table 9.7: 20 Straight Pipe + 5 Elbows x 2.75 + 2 Turns in Tees x 5.5 + 1 Swing Check x 7 + 2 valves x 0.6 = 52.95 Equivalent Feet Straight Pipe.
  • Page 47 Figure 9.3: Piping Method #1 - Heat + indirect Water Heater Figure 9.a: Piping Method #1 - secondary loop Piping (shaded)
  • Page 48 Figure 9.b: Piping Method #1 - indirect Water Heater loop Piping (shaded) TablE 9.: PiPE anD CirCulaTOr siZing FOr bOilEr lOOP BOILER BOILER LOOP PIPE SIZE TEMP RISE CIRCULATOR FLOW MAX EQUIVALENT MODEL (in NPT) (GPM) MODEL LENGTH (ft) Taco 007 FCM070 Taco 008 FCM070 Taco 0014 FCM090 Taco 0013 (Note #1) FCM090 Taco 0014 FCM120...
  • Page 49 TablE 9.: PiPE anD CirCulaTOr siZing FOr inDirECT WaTEr HEaTEr lOOP MAX. I.W.H. I.W.H. LOOP MAX BOILER PIPE ALLIANCE™ PRESSURE EQUIVALENT CIRCULATOR FLOW SIZE INDIRECT WATER MODEL DROP LENGTH MODEL HEATERS (in NPT) (GPM) (ft) (ft HEAD) AL27SL (*) AL35SL (*) Taco 008 FCM070 AL70SL (*) AL119SL (*) AL27SL, AL35SL AL50SL (*) Taco 0014 FCM090 AL70SL (*) AL119SL (*)
  • Page 50 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 flow rate through the boiler will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.1. For this reason, the pressure drop through the entire system must be known, added to the boiler pressure drop, and a circulator selected which will provide the required flow at the total calculated pressure drop. This method is generally not recommended because it is often very difficult to accurately calculate the pressure drop through the system. In replacement installations, it may be impossible to get an accurate measurement of the amount of piping and number of fittings in the system. In addition, if the system is zoned, the system flow may drop well below the minimum required when only one zone is calling for heat. The one advantage to this method is its installation simplicity. It may make sense to use this method when the boiler is to be installed with a new single zone system having a low-pressure drop. Pressure drop curves for the FCM Series boilers are shown in Figure 9.9. Calculation of the system pressure drop, and selection of the circulator, must be performed by someone having familiarity with pressure drop calculations, such as an HVAC engineer. Figure 9.8: Piping Method #2 - Direct Connection of boiler to Heating system...

  • Page 51: Standard Piping Installation Requirements

    Figure 9.9: boiler Head loss 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. If the valve is replaced, the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler. Pipe the discharge of the relief valve to a location where water or steam will not create a hazard or cause property damage if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve discharge is not piped to a drain, it must terminate at least 6 inches above the floor. Do not run relief valve discharge piping through an area that is prone to freezing. The termination of the relief valve discharge piping must be in an area where it is not likely to become plugged by debris. DangEr PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION. • DO NOT INSTALL A VALVE IN THE RELIEF VALVE DISCHARGE LINE. •...

  • Page 52: 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. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing. 4) Fill Valve (Required) - Either a manual or automatic fill valve may be used. The ideal location for the fill is at the expansion tank. 5) Automatic Air Vent (Required) - At least one automatic air vent is required. Manual vents will usually be required in other parts of the system to remove air during initial fill. 6) Manual Reset High Limit (Required by some codes) - This control is required by ASME CSD-1 and some other codes. Install the high limit in the boiler supply piping just above the boiler with no intervening valves. Set the manual reset high limit to 200°F. Wire the limit per Figures 10.1 & 10.2 in the Wiring section. 7) Flow Control Valve (Required) - The flow control valve prevents flow through the system unless the circulator is operating. Flow control valves are used to prevent gravity circulation or “ghost flows” in circulator zone systems through zones that are not calling for heat. 8) Isolation Valves (Recommended) - Isolation valves are useful when the boiler must be drained, as they will eliminate having to drain and refill the entire system. 9) Drain Valve (Required) - The drain valve is installed on the return tee located in the lower vestibule compartment as shown in Figure 9.2. 10) Low Water Cut-off (Required) - The low water cut-off supplied with this boiler must not be removed. D. Piping for Special Situations 1) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to an aluminum boiler such as the FCM. Some examples include: • Radiant systems that employ tubing without an oxygen barrier. • Systems with routine additions of fresh water. • Systems which are open to the atmosphere.
  • Page 53 Figure 9.10: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 9.11: Chiller Piping...

  • Page 54: Wiring

    X Wiring Warning All wiring and grounding must be done in accordance with the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code (ansi/nFPa 70). 1) Line Voltage (120 VAC) Connections (Figure 10.1) – The line voltage connections are located in the junction box on the right side of the vestibule: • Black – Line voltage “hot” • White – “Neutral” for boiler and circulators • Red – “Heating” circulator “hot” • Blue – “Indirect Water Heater “ circulator “hot”...
  • Page 56 Figure 10.2: ladder Diagram...
  • Page 57 Figure 10.3: Wiring of Isolation Relay for Control of Two Heating Circulators...

  • Page 58: Start-Up And Checkout

    XI Start-up and Checkout nOTE 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, flush the system to remove sediment, flux, and traces of boiler additives. This should be done with the boiler isolated from the system. 2) Fill the boiler and hydronic system with water meeting the following requirements below (also see the note on the next page): p H between 6.5 and 8.5 T otal Solids less than 2500 PPM H ardness less than 120 PPM (7 Grains/Gallon) P ressurize the system to at least 12 psi at the boiler...
  • Page 59 WATER QUALITY AND BOILER WATER ADDITIVES WATER QUALITY AND BOILER WATER ADDITIVES IMPORTANT NOTE IMPORTANT NOTE 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 Flush the system before connecting the boiler - In a replacement installation, fl ushing the system will remove Flush the system before connecting the boiler - In a replacement installation, fl ushing the system will remove 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 ux and may even contain sediment. 2) Make sure that the system is tight Make sure that the system is tight - Make sure that the system is tight - Make sure that the system is tight This is the single most important guideline. Tap water contains dissolved oxygen which causes corrosion. In a tight system, this oxygen comes out of solution and is quickly removed from the system through the automatic air vent. The system then remains essentially free of oxygen. If the system is not tight, however, frequent additions of make-up water can expose the heat exchanger to oxygen on...
  • Page 60 FCM Series Lighting and Operating Instructions...
  • Page 61 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 Meaning U.125 or Blank Checking internal software (power-up only) 1 0.SWT Boiler in standby. = Supply Water Temp. No call for heat. (After call for heat from heating thermostat) A.SWT Self-Check on Start-up 3 5.SWT 4 Blower and circulator on. Checking for adequate air flow. 1.SWT Prepurge 5 2.SWT Trial for ignition 6 3.SWT Flame established. Boiler responding to a call for heat. 7 8) Upon initial start-up, the gas train will be filled with air. Even if the gas line has been completely purged of air, it may take several tries for ignition before a flame is established. If more than 5 tries for ignition are needed, it will be necessary to press the reset button to restart the boiler. Once a flame has been established for the first time, subsequent calls for burner operation should result in a flame on the first try. 9) Inspect the flame visible through the window. On high fire the flame should be stable and mostly blue (Figure 11.1). No yellow tipping should be present; however, intermittent flecks of yellow and orange in the flame are normal. Figure 11.1: burner Flame 10) Check the inlet pressure and adjust if necessary. Verify that the inlet pressure is between the upper and lower limits shown on the rating plate with all gas appliances on and off.
  • Page 62 Figure 11.2: Gas Valve Detail 11) Perform a combustion test. Boilers equipped with a concentric vent system have a flue gas sample tap located in the boiler vent collar (under the screw cap). For other vent systems, the sample probe may be inserted into the terminal. If this is not possible, remove the flue temperature sensor and insert the analyzer probe in the sensor opening. For the boiler to operate, this sensor will need to be remain connected to the wiring. If the flue gas sensor is removed, be sure to replace it after combustion testing is complete. Check CO (or O ) and CO at both high and low fire. The boiler may be temporarily locked into high or low fire for 15 minutes as follows: a) To lock the boiler in high fire, simultaneously press and hold the “Mode” button and “+“ button until the display flashes “H”, indicating that the boiler has been driven to high fire. After this happens, allow the boiler to operate for approximately 5 minutes before taking combustion readings. b) To lock the boiler in low fire, simultaneously press and hold the “Mode” button and “-“ button until the display flashes “L”, indicating that the boiler has been driven to low fire. After this happens, allow the boiler to operate for approximately 5 minutes before taking combustion readings. c) Normal modulation of the boiler should return 15 minutes after the boiler is locked in high or low fire. At both high and low fire, CO readings should be less than 75 PPM. Typical CO readings are shown in Table 11.3. TablE 11.3: TYPiCal CO COMbusTiOn rEaDings Model Fuel FCM070 Natural Gas FCM070 Propane 10.4 FCM090 Natural Gas FCM090...
  • Page 63 Warning Each FCM series boiler is tested at the factory and adjustments to the air- fuel mixture are normally not necessary. Consult a U.S. Boiler representative before attempting to make any such adjustments. Improper gas valve or mixture adjustments could result in property damage, personal injury, or loss of life.

  • Page 64: Operation

    XII Operation 1) The FCM boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including flame 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. For more information on this feature see the discussion on boiler water reset below. The MCBA modulates the boiler input by varying the fan speed. As the fan speed increases, so does the amount of gas drawn into the blower. As a result, a fairly constant air-fuel ratio is maintained across all inputs. The MCBA determines the input needed by looking at both current and recent differences between the supply temperature and the set point temperature. As the supply temperature approaches the set point temperature, the fan will slow down and the input drop. Depending on the model boiler, the minimum input is between ¼ and 1/5 of maximum input. The MCBA also monitors boiler return and flue temperatures. In addition, all other safety controls, including the low water cut-off and safety limit, are connected into the MCBA. The MCBA uses input from all of these controls to either shut down the boiler when an unsafe condition exists or, in some cases, to correct the problem. 2) The display panel has three primary modes of operation. These are: • Standby Mode – Displays boiler’s current status. This is the default operating mode. • Parameter Mode – Used to change control settings • Information Mode – Displays boiler operating temperatures Under normal conditions, the boiler is in standby mode and the display looks like that shown in Figure 12.1. The three digits to the right of the decimal point are the boiler’s supply temperature. The digit to the left of the decimal point is the boiler’s status code. A list of status codes, and their meanings, is shown in Table 12.3. Figure 12.2 is a map of the menu structure for the control panel. Push the mode key to move from one mode to the next. As you change modes, the mode you are entering is shown on the display: a) “PArA” for Parameter Mode b) “Info” for Information Mode c) “Stby” for Standby Mode. Upon entering standby mode, “Stby” will briefly appear on the display and then the display will show the boiler’s status along with the supply temperature (Figure 12.1). The control will return to standby mode from any other mode if no key is pressed for 20 minutes. Figure 12.1: normal Display in standby Mode...
  • Page 65 In standby mode, it is possible to view both the heating supply set point temperature and the “domestic hot water reference set point”. The “domestic hot water reference set point” plus 45°F equals the boiler supply set point when it is responding to a call from the indirect water zone. 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. The “default domestic water reference set point” is 135°F and target boiler supply temperature when responding to a call from the indirect water heater is therefore 180°F (135°F +45°F). The default heating supply set point (parameter 4) is 180°F. In standby mode it is also possible to turn on or off either the heating or domestic water zone. There is normally no reason to turn off either of these zones and doing so is not recommended. CauTiOn PusHing anD HOlDing THE “+” WHilE in sTanDbY MODE Will PrEVEnT THE bOilEr FrOM rEsPOnDing TO a Call FOr HEaT. PusHing anD HOlDing THE “-” WHilE in sTanDbY MODE Will PrEVEnT THE bOilEr FrOM rEsPOnDing TO a Call FOr DOMEsTiC WaTEr.
  • Page 67 3) Two basic types of errors codes are shown on the display: • Soft Lockout Codes – 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. A list of these codes, and their meanings, is shown in Table 14.3. The boiler will automatically restart once the condition that caused the lockout is corrected. • Hard Lockout Codes – When a hard lockout occurs, the boiler will shut down and the display will flash the letter “E” followed by a two digit service code. A list of these codes, and their meanings, is shown in Table 14.4. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset using the RESET button on the display. TablE 12.3: bOilEr sTaTus First Digit boiler status Burner off - No call for heat or DHW Pre-purge or post-purge Ignition Burner responding to call for heat Burner responding to call for DHW Checking air pressure switch Burner off - Set point temperature has been reached Call for heat ended.
  • Page 68 d) After the prepurge, the control module energizes the gas control valve and the spark for 4.5 seconds. If a flame is established and proved, the control allows the flame to stabilize for 5 seconds at the combustion fan ignition speed setting. If the flame fails to prove, the control module will attempt to light the burner 4 more times. If a flame is still not established, the control will lockout. e) Once the flame stabilization period has ended, the MCBA allows the burner to modulate. The actual firing rate is dependent upon the measured current and recent differences between the set point temperature and the supply temperature. If an outdoor sensor is connected to the control module and the boiler is responding to a call for heat, the set point temperature will be determined by the outdoor reset curve shown in Figure 12.4. f) Once the set point temperature is reached, the MCBA will turn the burner off and allow the combustion fan to operate in postpurge for 35 seconds before it turns off. g) The central heating pump will continue to operate until the room thermostat has been satisfied. h) A demand for domestic hot water (DHW) is given priority on FCM Series boilers. If a call for DHW is received while the boiler is responding to a call for heat, the heating circulator is deenergized until the call for DHW is satisfied. Figure 12.4: Outdoor Reset Curve...

  • Page 69: Service And Maintenance

    XIII. Service and Maintenance iMPOrTanT 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 flammable vapors and liquids. b. Keep the area around the combustion air inlet terminal free from contaminates . c. Keep the boiler room ventilation openings open and unobstructed. 2) Monthly Inspections: a. Inspect the vent piping and outside air intake piping to verify they are open, unobstructed and free from leakage or deterioration. Call the service technician to make repairs if needed. b. Inspect the condensate drain system to verify it is leak tight, open and unobstructed. Call the service technician if the condensate drain system requires maintenance. c. Inspect the water and gas lines to verify they are free from leaks. Call the service technician to make repairs if required.
  • Page 70 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 significant 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). Vacuum these parts as required, being careful not to damage the vanes on the swirlplate. f. Remove the burner hood to access the burner and the combustion chamber. g. Remove the burner and vacuum any dust or lint from the burner. If the burner shows signs of deterioration or corrosion, replace it immediately. Inspect the burner gasket and replace, if necessary. h. Inspect the heat exchanger and vacuum any debris found on the pins and other surfaces. Clean the casting pins by flushing with clean water. A soft nylon brush may be used in accessible areas. Drain and flush the inside of the heat exchanger and condensate collector as required. Do not use any cleaning agents or solvents. i. Inspect the condensate trap to verify it is open and free from debris. Clean if necessary. j. Reinstall the burner, burner hood and fan/gas valve assembly. k. Reconnect any wiring which has been disconnected. l. Inspect the heating system and correct any other deficiencies prior to restarting the boiler. m. F ollow Section XI Start-up and Checkout instructions before leaving installation. n. Perform the combustion test outlined in Section XI. o. Verify that the system PH is between 6.5 and 8.5. p. Check for vent terminal obstructions and clean as necessary.

  • Page 71: Troubleshooting

    XIV. Troubleshooting Warning Turn off power to boiler before replacing fuses or working on wiring. A. Troubleshooting problems where no error code is displayed: TablE 1.1: nO ErrOr CODE DisPlaYED CONDITION POSSIBLE CAUSES • No 120VAC Power at boiler. Check breaker and wiring between breaker panel Display Blank, Fan off, LWCO lights off and boiler •...
  • Page 72 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. TablE 1.3: sOFT lOCKOuT CODEs DisPlaYED CODE CONDITION POSSIBLE CAUSES • Blockage in intake or vent system. • Vent and/or intake system not constructed in accordance with Part VI. • Blocked or leaking pressure switch tubing b 08 Pressure switch circuit open •...
  • Page 73 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 flash 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. TablE 1.: HarD lOCKOuT CODEs DisPlaYED CODE CONDITION POSSIBLE CAUSES A flame signal was present when there should • Defective gas valve - make sure inlet pressure is below maximum on rating plate E 00 be no flame.

  • Page 74: 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 76: Parts List

    ParTs lisT (Quantity) Part Number (Quantity) Part Number (Quantity) Part Number DESCRIPTION FCM070 FCM090 FCM120 (1) 8056170 Taco 007 ----- ----- (1) 100362-01 (1)100362-01 Taco 0014 ----- Gas Cock (1) 100487-01 (1) 100487-01 (1) 100487-01 M4 x 30mm Machine Screw (for gas valve harness) (1) 100364-01 (1) 100364-01 (1) 100364-01...
  • Page 78 ParTs lisT (Continued) (Quantity) Part Number DESCRIPTION FCM070 FCM090 FCM120 ½" x 11" Yellow Coated CSST, Nut by Nut (1) 100396-01 (1) 100396-01 (1) 100396-01 5/8" OD x 1/2" MPT CSST Adaptor (2) 100397-01 (2) 100397-01 (2) 100397-01 1/2" Blk Elbow (1) 100539-01 (1) 100539-01 (1) 100539-01...
  • Page 82 ParTs lisT (Continued) (Quantity) Part Number DESCRIPTION FCM070 FCM090 FCM120 (1) 100450-01 (1) 100450-01 (1) 100450-01 DISP4D Graphic Overlay Mounting Plate (1)100452-01 (1)100452-01 (1)100452-01 8-32 Lock Nut (4) 100449-01 (4) 100449-01 (4) 100449-01 Zinc Plated Brass Spacer (4) 101031-01 (4) 101031-01 (4) 101031-01 8-32 x ¾"...

  • Page 86: 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 IMPORTANT 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 finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: 1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors. a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level. b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed. 2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.
  • Page 87 1. Detailed instructions for the installation of the venting system design or the venting system components; 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer: 1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and 2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions. (e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

  • Page 88: Limited Warranty

    Burnham Hydronics Repair Parts Price Sheet 8. Limitation of Warranties: These warranties set forth the entire obligation of U.S.

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