Burnham 101008-01R1-2/07 manual

D N A G N I T A R E P O , N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S ™ M O D E E R F Y C N E I C I F F E H G I H G N I S N E D N O C T N E V T C E R I D R E L I O B R E T A W T O H D E R I F - S A G W ARNING: Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury , or loss [...]

2 T able of Contents I. Product Description ............................................................................ 2 II. Speci fi cations ..................................................................................... 2 III. Before Installing .................................................................................. 3 IV . Loca[...]

3 I Pr oduct 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. B[...]

4 III Befor e 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, AN[...]

5 6) The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will contaminate combustion air . A void areas near chemical products containing chlorine, chloride based salts, chloro/ fl uorocarbons, paint removers, cleaning solvents and detergents. Figure 4.1: Clearances T o Combustible Or Non[...]

6 T ABLE 4.2: CLEARANCES FROM VENT PIPING T O COMBUSTIBLE CONSTRUCTION TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE TO COMBUSTIBLE MA TERIAL 60/100mm CONCENTRIC VENTING VERTICAL OR HORIZONT AL ENCLOSED ON ALL FOUR SIDES 0” HEA T F AB SAF-T VENT PROTECH F ASNSEAL Z-FLEX Z-VENT III FLEX-L ST AR-34 VERTICAL OR HORIZONT AL A T LEAST O[...]

7 V Mounting The Boiler CAUTIO N T his boiler wei g hs approximatel y 1 10 pounds : • T wo people are required to safel y lift this boiler onto the wall mountin g hook . • Make sure that wall mountin g hook is anchored to a structure capable of supportin g the wei g ht of the boiler and attached pipin g when fi lled with water . Jurisdictions [...]

8 Fi g ure 5.1 W all Mountin g Hole Locations[...]

9 Fi g ure 5.2 Boiler Mountin g/ Hardwar e[...]

10 VI Air for V entilation W ARNING OUTDOOR COMBUSTION AIR MUST BE PIPED TO THE AIR INT AKE. NEVER PIPE COMBUSTION AIR FROM AREAS CONT AINING CONT AMINA TES SUCH AS SWIMMING POOLS AND LAUNDR Y ROOM EXHAUST VENTS. CONT AMINA TED COMBUSTION AIR WILL DAMAGE THE BOILER AND MA Y CAUSE PROPERTY DAMAGE, PERSONAL INJUR Y OR LOSS OF LIFE. Air for combustion[...]

11 Figure 6.1: Boiler Installed In A Con fi ned Space, V entilation Air From Inside[...]

12 A. V ent System Design There are three basic ways to vent this boiler: • Horizontal (“Side W all”) Concentric V enting - V ent system exits the building through an outside wall. Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion air is drawn into the boiler through t[...]

13 shown in T able 7.1 are in addition to the fi rst elbow on top of the boiler . For vertical vent systems, the maximum vertical vent lengths shown in T able 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 T able 7.7 for each additional elbow used. T erminatio[...]

14 T ABLE 7.1: SUMMAR Y OF HORIZONT AL VENTING OPTIONS VENT OPTION # 1 2 3 4 CLASSIFICA TION USED IN THIS MANUAL HORIZONT AL CONCENTRIC HORIZONT AL TWIN PIPE (RESER VED FOR FUTURE USE) (RESER VED FOR FUTURE USE) ILLUSTRA TED IN FIGURE 7.2 7.3 VENT PIPE STRUCTURE PENETRA TION W ALL W ALL AIR INT AKE PIPE STRUCTURE PENETRA TION W ALL W ALL VENT PIPE [...]

15 Figure 7.2: Horizontal Concentric V enting (V ent Option 1) Figure 7.3: Horizontal T win Pipe V enting (V ent Option 2)[...]

16 T ABLE 7.4: U.S. BOILER CONCENTRIC VENT COMPONENTS (VENT OPTION 1) P AR T NO. DESCRIPTION SIZE USED ON VENT OPTION # COMMENTS 101005-01 80/125 x 60/100mm REDUCING ELBOW 80/125 x 60/100mm 1 INCLUDED WITH ST ANDARD BOILER 101006-01 TERMINAL SECTION 60/100mm 1 INCLUDED WITH ST ANDARD BOILER 101007-01 W ALL GROMMET 60/100mm 1 INCLUDED WITH ST ANDARD[...]

17 Figure 7.6a: Location of V ent T erminal Relative to Windows, Doors, Grade Figure 7.6b: Location of V ent T erminal Relative to Meters and Forced Air Inlets Figure 7.6c: Positioning V ent T erminal Under Overhangs[...]

18 T ABLE 7.7: VENT/ AIR INT AKE FITTING EQUIV ALENT LENGTH VENT FITTING EQUIV ALENT 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 6) Permitted T erminals for V ertical V enting (V ent Option 5) - A straight termination is installed in the end of the vent pipe. V ent manufacturer p[...]

19 T ABLE 7.8: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 5 6 CLASSIFICA TION USED IN THIS MANUAL VER TICAL TWIN PIPE (RESER VED FOR FUTURE USE) ILLUSTRA TED IN FIGURE 7.9 VENT PIPE STRUCTURE ROOF AIR INT AKE PIPE STRUCTURE ROOF VENT PIPE SIZE 3” AIR INT AKE PIPE SIZE 3” MAXIMUM LENGTH VENT FCM070 49.5ft FCM090 49.5ft FCM120 49.5ft INLET[...]

20 B. Removing an Existing Boiler Fr om 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[...]

21 C. Assembly of U.S. Boiler 60/100mm Concentric V enting 1) Concentric vent components supplied with the boiler are packed inside the boiler carton and include the following: a) 80/125 x 60/100mm reducing elbow (P/N 101005-01). b) 60/100mm terminal section (straight section with a terminal and overall length of 27 3/4” (P/N 101006-01). c) (2) R[...]

22 Figure 7.10: Installation of Reducing Elbow on Concentric Boiler Collar Figure 7.1 1: Dimension “L”[...]

23 6) Use locking bands provided to join adjacent sections of non-cuttable pipe as well as fi ttings. 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 [...]

24 Figure 7.14: Preparing T erminal Section for Installation in the W all Figure 7.15: Attaching T erminal Section[...]

25 D. Assembly of Stainless Steel V enting CAUTION V ent 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 [...]

26 3) Assembly of Flex-L-Intl. Star-34 V ent System: a) Star-34 General Notes: • Do not cut Star-34 vent components. • Support horizontal piping sections at intervals of 48” or less. • V ertical venting systems must be supported by at least one Star-34 Fire stop. An additional vertical support is required after any offset. • Orient Star-3[...]

27 4) Assembly of Z-Flex Z-V ent 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 hor[...]

28 5) Assembly of Heat Fab Saf-T V ent EZ Seal: a) Saf-T V ent General Notes: • These instructions cover the installation of Saf-T V ent EZ Seal. Saf-T V ent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints. • In general, Saf-T V ent pipe sections may not be cut. Exceptions to this are the Saf-T[...]

29 6) Assembly of Protech FasNSeal a) FasNSeal General Notes: • Do not cut 4” FasNSeal pipe. Consult FasNSeal instructions for method of cutting other 3” pipe. • Orient FasNSeal vent components so that the arrows on the piping labels are in the direction of fl ue gas fl ow . • Support horizontal piping sections at intervals of 6 feet or[...]

30 8) Installation of V ertical Exhaust T erminal - Use the terminal supplied by the vent system manufacturer shown in T able 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 T erminals: a) Assemble the air intake system u[...]

31 Figure 7.21: Condensate Piping Arrangement[...]

32 VIII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fi re at the nameplate input at an inlet pressure between the minimum and maximum values shown on the rating plate. For more information on gas line sizing, consult the utility or the National Fuel Gas Code. Figure 8.1 shows typical gas piping conne[...]

33 IX System Piping A. General System Piping Precautions W ARNING INST ALL BOILER SO THA T THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM W A TER (DRIPPING, SPRA YING, RAIN, ETC) DURING APPLIANCE OPERA TION AND SERVICE (CIRCULA TOR REPLACEMENT , ETC). CAUTION THE HEA T EXCHANGER USED IN THE FCM IS MADE FROM A SPECIAL ALUMINUM ALLOY . F AILUR[...]

34 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 fl ow is always maintained through the boiler . In this system, the fl ow rate through the boiler is com[...]

35 Figure 9.2: Piping Method #1 - Heat Only Example (contd.) T otal fi ttings in Indirect W ater Heater Loop: 5 90 Elbows 2 T urns in T ees 1 Swing Check 2 Isolation V alves Calculate total equivalent length fr om T able 9.7: 20 Straight Pipe + 5 Elbows x 2.75 + 2 T urns in T ees x 5.5 + 1 Swing Check x 7 + 2 valves x 0.6 = 52.95 Equivalent Feet S[...]

36 Figure 9.3: Piping Method #1 - Heat + Indirect W ater Heater Figure 9.4a: Piping Method #1 - Secondary Loop Piping (Shaded)[...]

37 Figure 9.4c: Modular Boiler Piping Figure 9.4b: Piping Method #1 - Indirect W ater Heater Loop Piping (Shaded)[...]

38 T ABLE 9.6: PIPE AND CIRCULA TOR SIZING FOR INDIRECT W A TER HEA TER LOOP BOILER MODEL (a) (b) (c) (d) (e) (f) PIPE SIZE FLOW MAX. I.W .H. PRESSURE DROP ALLIANCE™ INDIRECT W A TER HEA TERS CIRCULA TOR MODEL I.W .H. LOOP MAX EQUIV ALENT LENGTH (in NPT) (GPM) (ft HEAD) (ft) FCM070 1 6.0 1.7 AL27SL (*) AL35SL (*) AL70SL (*) AL1 19SL (*) T aco 008[...]

39 Method 2: Direct Connection to Heating System (Generally NOT Recommended) The FCM can be connected directly to the heating system as is done with conventional boilers (Figure 9.8). If this is done, the fl ow rate through the boiler will equal the fl ow rate through the system. The fl ow rate through the system must therefore always remain wit[...]

40 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 r[...]

41 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 T ank (Required) - If this boiler is replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reus[...]

42 Figure 9.1 1: Chiller Piping Figure 9.10: Isolation of the Boiler From Oxygenated W ater with A Plate Heat Exchanger[...]

43 1) Line V oltage (120 V AC) Connections (Fig 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 W ater Heater “ circulator ?[...]

44 Figure 10.1: Wiring Connections Diagram[...]

45 Figure 10.2: Ladder Diagram[...]

46 Figure 10.3: Wiring of Isolation Relay for Control of T wo Heating Circulators[...]

47 XI Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) If not already done, fl ush the system to remove sediment, fl ux, and traces of boiler additives. This should be done with the boiler isolated from the system. 2) Fill the boiler and hydronic system with water meeting the following requirements below (a[...]

48 W A TER QUALITY AND BOILER W A TER ADDITIVE S I MP O RT A N T N O T E This boiler is equipped with an aluminum heat exchan g er that can be seriousl y dama g ed b y failure to follow t he following guidelines : 1 ) Flush the system before connecting the boiler yg - In a replacement installation, fl ushing the system will remove r s ediment, sol[...]

49 FCM Series Lighting and Operating Instructions[...]

50 10) Check the inlet pressure and adjust if necessary . V erify that the inlet pressure is between the upper and lower limits shown on the rating plate with all gas appliances on and off. W ARNING THE OUTLET PRESSURE FOR THE GAS V AL VE HAS BEEN F ACTOR Y SET AND REQUIRES NO FIELD ADJUSTMENT . THIS SETTING IS SA TISF ACTOR Y FOR BOTH NA TURAL GAS[...]

51 1 1) Perform a combustion test. Boilers equipped with a concentric vent system have a fl ue 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 fl ue temperature sensor and insert the analyzer probe in the sensor [...]

52 W ARNING 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. 12) T est any external li[...]

53 XII Operation 1) The FCM boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including fl ame supervision and modulation. T wo 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 temperat[...]

54 CAUTION PUSHING AND HOLDING THE “+” WHILE IN ST ANDBY MODE WILL PREVENT THE BOILER FROM RESPONDING TO A CALL FOR HEA T . PUSHING AND HOLDING THE “-” WHILE IN ST ANDBY MODE WILL PREVENT THE BOILER FROM RESPONDING TO A CALL FOR DOMESTIC W A TER. IF THIS HAPPENS, “cOFF” or “dOFF” WILL APPEAR ON THE DISPLA Y . TO TURN BACK ON THE HEA[...]

55 FIGURE 12.2 BASIC MENU TREE[...]

56 3) T wo 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 T able 14.3. The boiler will a[...]

57 d) After the prepurge, the control module ener gizes the gas control valve and the spark for 4.5 seconds. If a fl ame is established and proved, the control allows the fl ame to stabilize for 5 seconds at the combustion fan ignition speed setting. If the fl ame fails to prove, the control module will attempt to light the burner 4 more times. [...]

58 XIII. Service and Maintenance IMPORT ANT W ARRANTY DOES NOT COVER BOILER DAMAGE OR MALFUNCTION IF THE FOLLOWING STEPS ARE NOT PERFORMED A T THE INTERV ALS SPECIFIED 1) Continuously: a. Keep the area around the boiler free from combustible materials, gasoline and other fl ammable vapors and liquids. b. Keep the area around the combustion air inl[...]

59 d. Remove the ignition electrode and inspect it for oxides. Clean the oxides off the electrode with sandpaper . Inspect the ceramic insulator for cracks and replace the ignitor assembly if necessary . e. Remove the fan/gas valve assembly from the burner hood. Inspect for lint and dust. If signi fi cant lint and dust are found, disassemble the f[...]

60 XIV . T roubleshooting A. T roubleshooting problems where no error code is displayed: T ABLE 14.1: NO ERROR CODE DISPLA YED CONDITION POSSIBLE CAUSES Display Blank, Fan off, L WCO lights off • No 120V AC Power at boiler . Check breaker and wiring between breaker panel and boiler Display Panel Blank, Fan running • Loose 120V AC connection wir[...]

61 T ABLE 14.3: SOFT LOCKOUT CODES DISPLA YED CODE CONDITION POSSIBLE CAUSES b 08 Pressure switch circuit open • Blockage in intake or vent system. • V ent and/or intake system not constructed in accordance with Part VI. • Blocked or leaking pressure switch tubing • Heat exchanger or burner blockage • T erminals exposed to high winds • [...]

62 T ABLE 14.4: HARD LOCKOUT CODES DISPLA YED CODE CONDITION POSSIBLE CAUSES E 00 A fl ame signal was present when there should be no fl ame. • Defective gas valve - make sure inlet pressure is below maximum on rating plate before replacing valve. E 02 Flame failure after 5 tries to restart • No gas pressure • Gas pressure under minimum val[...]

63 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.[...]

64[...]

65 KEY DESCRIPTION (Quantity) Part Number (Quantity) Part Number (Quantity) Part Number FCM070 FCM090 FCM120 * T aco 007 (1) 8056170 ----- ----- * T aco 0014 ----- (1) 100362-01 (1)100362-01 * 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 * Outdoor Sens[...]

66[...]

67 KEY DESCRIPTION (Quantity) Part Number FCM070 FCM090 FCM120 46 ½" x 1 1" Y ellow Coated CSST , Nut by Nut (1) 100396-01 (1) 100396-01 (1) 100396-01 47 5/8" OD x 1/2" MPT CSST Adaptor (2) 100397-01 (2) 100397-01 (2) 100397-01 48 1/2" Blk Elbow (1) 100539-01 (1) 100539-01 (1) 100539-01 49 Flanged Nipple Assy . (1) 100398-[...]

68[...]

69[...]

70[...]

71 KEY DESCRIPTION (Quantity) Part Number FCM070 FCM090 FCM120 102 DISP4D (1) 100450-01 (1) 100450-01 (1) 100450-01 103 Graphic Overlay Mounting Plate (1)100452-01 (1)100452-01 (1)100452-01 104 8-32 Lock Nut (4) 100449-01 (4) 100449-01 (4) 100449-01 105 Zinc Plated Brass Spacer (4) 101031-01 (4) 101031-01 (4) 101031-01 106 8-32 x ¾" Round Hea[...]

72 150 151 152 153 154 155[...]

73 156 157 158 159 160 161[...]

74 162[...]

75 NOTES[...]

76 Appendix A: Special Requir ements For Side-W all V ented Appliances In The Commonwealth of Massachusetts IMPOR T ANT 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 i[...]

77 (d) MANUF ACTURER 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 fl ue gases, but identi fi es “special venting systems”, the following requirements shall be satis fi ed by the manufacturer: [...]

78 NOTES[...]

79 NOTES[...]

e. Boilers installed outside the 48 contiguous United States, the State of Alaska, and Canada. f. Damage to the boiler and /or proper ty due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instr uction manual. g. Any damage of failure of the boiler resulting from hard water or scale bu[...]