IN S TAL L AT ION , OP E R AT IN G AN D S E R V IC E IN S T R U C T ION S F OR F R E E D OM ™ C ON D E N S IN G H IGH E F F IC IE N C Y D IR E C T V E N T GA S - F I R E D H OT WAT E R BOI L E R Model: FCM120 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.
Table of Contents I. II. III. IV. V. VI. VII. VIII. IX. X. XI. XII. XIII. XIV. XV. 2 Product Description ............................................................................ 2 Specifications ..................................................................................... 2 Before Installing .................................................................................. 3 Locating The Boiler.............................................................................
I Product Description The FCM090 and FCM120 are aluminum gas fired 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 floor 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.
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.
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 4.
TABLE 4.
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 filled with water. Jurisdictions in areas subject to earthquakes may have special requirements for supporting this boiler. These local requirements take precedence over the requirements shown below. A.
Figure 5.
Figure 5.
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. Air for combustion must always be obtained directly from outdoors, however sufficient air for ventilation must still be provided in the boiler room.
Figure 6.
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 Table 7.6 * Do not attempt to mix components from different approved vent systems. * Do not obtain combustion air from within the building. * Do not install a barometric damper or drafthood on this boiler.
shown in Table 7.1 are in addition to the first elbow on top of the boiler. For vertical vent systems, the maximum vertical vent lengths shown in Table 7.8 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 7.7 for each additional elbow used. Termination fittings are never counted, although the length of the concentric terminal section, included with the boiler, is counted.
TABLE 7.1: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 1 CLASSIFICATION USED IN THIS MANUAL ILLUSTRATED IN FIGURE HORIZONTAL TWIN PIPE 7.2 7.
Figure 7.2: Horizontal Concentric Venting (Vent Option 1) Figure 7.
TABLE 7.4: U.S. BOILER CONCENTRIC VENT COMPONENTS (VENT OPTION 1) USED ON VENT OPTION # COMMENTS 80/125 x 60/100mm 1 INCLUDED WITH STANDARD BOILER TERMINAL SECTION 60/100mm 1 INCLUDED WITH STANDARD BOILER WALL GROMMET 60/100mm 1 INCLUDED WITH STANDARD BOILER PART NO.
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.
TABLE 7.7: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH VENT FITTING 6) EQUIVALENT LENGTH (ft) 60/100mm 90 CONCENTRIC ELBOW 4.5 60/100mm 45 CONCENTRIC ELBOW 4.0 3” 90 ELBOW 5.5 3” 45 ELBOW 4.0 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.
TABLE 7.8: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 5 CLASSIFICATION USED IN THIS MANUAL ILLUSTRATED IN FIGURE VERTICAL TWIN PIPE ROOF AIR INTAKE PIPE STRUCTURE PENETRATION ROOF 3” AIR INTAKE PIPE SIZE 3” INLET VENT INLET VENT VENT PIPE SIZE MAXIMUM LENGTH (RESERVED FOR FUTURE USE) 7.9 VENT PIPE STRUCTURE PENETRATION MINIMUM LENGTH 6 FCM090 FCM120 49.5ft FCM090 FCM120 49.
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.
C. Assembly of U.S. Boiler 60/100mm Concentric Venting 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 • Do not lubricate concentric gaskets with anything other than water. • Do not attempt to cut any piping except as permitted in this section. When cutting these sections, make sure all cuts are square and allow for proper insertion.
Figure 7.10: Installation of Reducing Elbow on Concentric Boiler Collar Figure 7.
6) Use locking bands provided to join adjacent sections of 39” pipe as well as fittings. 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. 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”.
Figure 7.14: Preparing Terminal Section for Installation in the Wall Figure 7.
D. 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. • Make sure that both the male and female pipes are free of damage prior to assembly. • Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions.
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. • Orient Star-34 components so that the arrows on the piping labels are in the direction of flue gas flow. b) Start assembly of the vent system at the boiler.
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.
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.
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. • b) c) d) e) f) g) Vertical venting systems must be supported by at least one FasNSeal support. An additional vertical support is required after any offset.
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) b) c) d) Assemble the air intake system using either galvanized or PVC pipe. If PVC piping is used, use PVC cement to assemble the PVC intake system components.
Figure 7.
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.
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.
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.
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. 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.
Figure 9.3: Piping Method #1 - Heat + Indirect Water Heater Figure 9.
Figure 9.4b: Piping Method #1 - Indirect Water Heater Loop Piping (Shaded) Figure 9.
TABLE 9.5: PIPE AND CIRCULATOR SIZING FOR BOILER LOOP (a) (b) (c) PIPE SIZE FLOW TEMP RISE (in NPT) (GPM) (F) FCM090 1 8.0 FCM090 1 FCM120 FCM120 FCM120 BOILER MODEL (d) (e) CIRCULATOR MODEL BOILER LOOP MAX EQUIVALENT LENGTH (ft) 21 Taco 0014 90 8.0 21 Taco 0013 (Note #1) 230 1 8.0 29 Taco 0014 111 1 1 9.0 12.0 25 19 Taco 0014 Taco 0013 (Note #1) 61 28 NOTE: 1) Use isolation relay between Taco 0013 and FCM - see Figure 10.3 TABLE 9.
TABLE 9.7: FITTING EQUIVALENT LENGTHS PIPE SIZE EQUIVALENT LENGTH (ft) 90 ELBOW 1 2.75 TURN IN TEE 1 5.50 RUN OF TEE 1 1.75 SWING CHECK GATE VALVE 1 1 7.00 0.60 FITTING 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.
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.
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.
Figure 9.10: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger Figure 9.
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 (Fig 10.
Figure 10.
Figure 10.
Figure 10.
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.
WATER QUALITY AND BOILER WATER ADDITIVES 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 y before connecting g the boilerr - In a replacement installation, flushing the system will remove sediment, solder flux, and traces of old boiler additives. Even if the system is new, do not omit this step - new systems will contain solder flux and may even contain sediment.
FCM Series Lighting and Operating Instructions 49
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 1 U.125 or Blank Checking internal software (power-up only) 2 0.SWT Boiler in standby. SWT = Supply Water Temp. No call for heat. (After call for heat from heating thermostat) A.SWT Self-Check on Start-up 3 4 5.SWT Blower and circulator on. Checking for adequate air flow. 5 1.SWT Prepurge 6 2.SWT Trial for ignition 7 3.SWT Flame established.
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.
WARNING Each FCM series boiler is tested at the factory and adjustments to the airfuel 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. 12) Test any external limits or other controls in accordance with the manufacturer’s instructions.
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.
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.
FIGURE 12.
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.
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.
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.
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).
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 14.1: NO ERROR CODE DISPLAYED CONDITION POSSIBLE CAUSES Display Blank, Fan off, LWCO lights off • No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler Display Panel Blank, Fan running • Loose 120VAC connection wiring between boiler J-Box and MCBA • Blown “F1” fuse in MCBA (see Figure 13.2 for location).
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 14.3: SOFT LOCKOUT CODES DISPLAYED CODE CONDITION POSSIBLE CAUSES Pressure switch circuit open • Blockage in intake or vent system.
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 14.4: HARD LOCKOUT CODES DISPLAYED CODE CONDITION POSSIBLE CAUSES A flame signal was present when there should be no flame.
XV 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 Service at (717) 481-8400 or Fax (717) 481-8408.
PARTS LIST KEY DESCRIPTION FCM090 FCM120 U.S. BOILER PART # QUANTITY U.S.
PARTS LIST (Continued) FCM090 KEY DESCRIPTION FCM120 U.S. BOILER PART # QUANTITY U.S. BOILER PART # QUANTITY 1 46 ½" x 11" Yellow Coated CSST, Nut by Nut 100396-01 1 100396-01 47 5/8" OD x 1/2" MPT CSST Adaptor 100397-01 2 100397-01 2 48 1/2" Blk Elbow 100539-01 1 100539-01 1 49 Flanged Nipple Assy.
PARTS LIST (Continued) KEY DESCRIPTION FCM090 FCM120 U.S. BOILER PART # QUANTITY U.S.
150 151 152 153 154 155
156 157 158 159 160 161 73
162 74
NOTES 75
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.
(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.
NOTES 78
NOTES 79
