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Burnham FREEDOM FCM120, Installation, Operating And Service Instructions

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Burnham FREEDOM FCM120 Installation, Operating And Service Instructions Download Page 2

2

Table of Contents

 

I. Product 

Description 

............................................................................ 2

 II. 

Speci

fi

 cations ..................................................................................... 2

 III. 

Before 

Installing 

.................................................................................. 3

 IV. 

Locating 

The 

Boiler 

............................................................................. 3

 V. 

Mounting 

The 

Boiler 

........................................................................... 7

 

VI.  Air For Ventilation .............................................................................. 10

 VII. Venting 

............................................................................................... 11

 

  A.  Vent System Design ................................................................... 12

 

  B.  Removing An Existing Boiler From Common Chimney .............. 20

 

  C.  Assembly of 60/100mm Concentric Venting ............................... 21

 

  D.  Assembly of Stainless Steel Venting .......................................... 25

 

  E.  Condensate Trap and Drain ....................................................... 30

 VIII. Gas 

Piping 

......................................................................................... 32

 IX. 

System 

Piping 

.................................................................................... 33

 

  A.  General System Piping Precautions ........................................... 33

  

B. 

System 

Design 

........................................................................... 33

 

  C.  Standard Piping Installation Requirements ................................ 40

 

  D.  Piping For Special Situations ...................................................... 41

 X. 

Wiring 

 ................................................................................................ 43

 

XI.  Start-up and Checkout ....................................................................... 47

 XII. Operation 

........................................................................................... 53

  XIII.  Service and Maintenance .................................................................. 58
 XIV. Troubleshooting 

................................................................................. 60

 XV. Parts 

 

................................................................................................ 63

  

Appendix 

A

 

   

Special Requirements For Side-Wall Vented 

 

Appliances In The Commonwealth of Massachusetts .................. 76

 Warranty 

............................................................................. Back 

Cover

Summary of Contents for FREEDOM FCM120

Page 1: ... R E L I O B R E T A W T O H D E R I F S A G 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 01 12 06 ...

Page 2: ...1 D Assembly of Stainless Steel Venting 25 E Condensate Trap and Drain 30 VIII Gas Piping 32 IX System Piping 33 A General System Piping Precautions 33 B System Design 33 C Standard Piping Installation Requirements 40 D Piping For Special Situations 41 X Wiring 43 XI Start up and Checkout 47 XII Operation 53 XIII Service and Maintenance 58 XIV Troubleshooting 60 XV Parts 63 Appendix A Special Requ...

Page 3: ...ems containing significant amounts of dissolved oxygen II Specifications TABLE 2 2 SPECIFICATIONS MODEL NO OF SECTIONS MAXIMUM INPUT BTU hr MINIMUM INPUT BTU hr D O E HEATING CAPACITY BTU hr IBR NET RATING BTU hr AFUE WATER VOLUME Gal APPROX NET WEIGHT lb FCM120 mono block 120 000 40 000 107 000 93 95 2 0 62 110 Add suffix N for natural gas and P for propane Ratings are the same for both fuels Usi...

Page 4: ... 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 require...

Page 5: ...r 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 1 Clearances To Combustible Or Non combustible Material ...

Page 6: ...HEAT FAB SAF T VENT PROTECH FASNSEAL Z FLEX Z VENT III FLEX L STAR 34 VERTICAL OR HORIZONTAL AT LEAST ONE SIDE OPEN COMBUSTIBLE MATERIAL ON A MAXIMUM OF THREE SIDES 1 HEAT FAB SAF T VENT PROTECH FASNSEAL Z FLEX Z VENT III FLEX L STAR 34 HORIZONTAL OR VERTI CAL WITH OFFSETS ENCLOSED ON ALL FOUR SIDES 2 1 2 HEAT FAB SAF T VENT PROTECH FASNSEAL Z FLEX Z VENT III FLEX L STAR 34 VERTICAL WITH NO OFF SE...

Page 7: ...at wall selected does not have any framing or other construction that will interfere with the vent pipe penetration 5 Once a suitable location has been selected for the boiler and any needed modifications have been made to the wall use Figure 5 1 to locate holes A and B Make sure that the horizontal centerline of these holes is level Holes C and D may also be drilled at this time or after the boil...

Page 8: ...8 Figure 5 1 Wall Mounting Hole Locations ...

Page 9: ...9 Figure 5 2 Boiler Mounting Hardware ...

Page 10: ...is a confined space Example A FCM120 and a water heater are to be installed in a room measuring 6 ft 3 in x 7 ft with an 8 ft ceiling The water heater has an input of 30000 BTU hr Total input in thousands of BTU hr 120000 BTU hr 30000 BTU hr 1000 150 MBTU hr Volume of room 6 25 ft x 7 ft x 8 ft 350 ft3 350 150 2 33 Since 2 33 is less than 50 the boiler room is a confined space Step 2a If the boile...

Page 11: ...11 Figure 6 1 Boiler Installed In A Confined Space Ventilation Air From Inside ...

Page 12: ...egral gaskets on each concentric fitting provide a gas tight seal A list of all U S Boiler concentric vent components is shown in Table 7 4 In this manual concentric pipe sizes are called out in terms of the inner and outer pipe nominal diameters in millimeters For example 60 100mm pipe consists of a 60mm exhaust pipe inside a 100mm diameter outer pipe Twin Pipe Vent Systems Approved vent systems ...

Page 13: ...as the rest of the air inlet system either galvanized or PVC and is installed as shown in Figure 7 3 5 Horizontal Vent and Air Intake Terminal Location Observe the following limitations on the vent terminal location also see Figure 7 6 When locating a concentric terminal observe the limitations outlined below for vent terminals Vent terminals must be at least 1 foot from any door window or gravity...

Page 14: ...IPE STRUCTURE PENETRATION WALL WALL VENT PIPE SIZE 60 100 mm CONCENTRIC 3 AIR INTAKE PIPE SIZE 3 MAXIMUM LENGTH VENT FCM090 FCM120 18ft 55ft INLET FCM090 FCM120 18ft 55ft MINIMUM LENGTH VENT FCM090 FCM120 10in 2ft INLET FCM090 FCM120 10in 2ft VENT TERMINAL 60 100 mm CONCENTRIC P N 8110701 AIR INTAKE TERMINAL 3 90 ELBOW VENT MATERIAL U S Boiler 60 100mm VENT COMPONENTS SHOWN IN TABLE 7 4 APPROVED S...

Page 15: ...15 Figure 7 2 Horizontal Concentric Venting Vent Option 1 Figure 7 3 Horizontal Twin Pipe Venting Vent Option 2 ...

Page 16: ...MANUFACTURER VENT SYSTEM SIZE COMPONENT PART NUMBER HEAT FAB SAF T VENT EZ SEAL 3 BOILER COLLAR 101004 01 3 WALL THIMBLE HEAT FAB 7393 7393GCS 5391CI 3 HORIZONTAL TERMINAL 8110701 3 VERTICAL TERMINAL HEAT FAB 9392 PROTECH SYSTEMS INC FASNSEAL 3 BOILER COLLAR 101004 01 3 WALL THIMBLE FSWT3 3 HORIZONTAL TERMINAL 8110701 3 VERTICAL TERMINAL FSBS3 Z FLEX SVE SERIES III Z VENT III 3 BOILER COLLAR 10100...

Page 17: ... Figure 7 6a Location of Vent Terminal Relative to Windows Doors Grade Figure 7 6b Location of Vent Terminal Relative to Meters and Forced Air Inlets Figure 7 6c Positioning Vent Terminal Under Overhangs ...

Page 18: ... 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 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...

Page 19: ...KE PIPE STRUCTURE PENETRATION ROOF VENT PIPE SIZE 3 AIR INTAKE PIPE SIZE 3 MAXIMUM LENGTH VENT FCM090 FCM120 49 5ft INLET FCM090 FCM120 49 5ft MINIMUM LENGTH VENT FCM090 FCM120 2ft INLET FCM090 FCM120 2ft VENT TERMINAL STRAIGHT TERMINAL BY VENT SYSTEM MFR TABLE 7 5 AIR INTAKE TERMINAL 3 180 ELBOW FIGURE 7 9 VENT MATERIAL APPROVED STAINLESS STEEL VENT SYSTEM SHOWN IN TABLE 7 5 AIR INTAKE MATERIAL G...

Page 20: ...n 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 fo...

Page 21: ...e De burr the cut edge of the plastic pipe with a file razor blade or fine sandpaper f Reinstall the inner pipe in the terminal section Slip the outside wall grommet over the terminal section and position so that it covers the joint between the outer pipe and the terminal Figure 7 14 g Make a mark on the terminal section 1 from the cut end of the outer pipe as shown in Figure 7 14 h Pass the termi...

Page 22: ...22 Figure 7 10 Installation of Reducing Elbow on Concentric Boiler Collar Figure 7 11 Dimension L ...

Page 23: ...ter pipe remove the plastic inner pipe by pulling it out from the female end b Cut the outer pipe only at the point marked in Step b 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 c Cut the plastic inner pipe so that it will protrude 3 8 beyond the outer pipe when reinstalled in the outer pipe Use a fine ...

Page 24: ...24 Figure 7 14 Preparing Terminal Section for Installation in the Wall Figure 7 15 Attaching Terminal Section ...

Page 25: ...d not be placed at the bottom of horizontal sections of exhaust pipe c Do not drill holes in vent pipe d Do not attempt to mix vent components of different vent system manufacturers 2 Mounting Stainless steel vent collar The use of stainless steel venting requires the stainless steel vent collar which replaces the 80 125mm concentric collar supplied with the boiler To install the stainless steel v...

Page 26: ...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 Clean the female end of the first piece of pipe Also clean the male end of the next piece of pipe i Apply silicone as in step d Fig 7 17b j Align the longitudinal seams of the pipe and insert the male end ...

Page 27: ...mately inch from the male end of the pipe Apply beads of silicone along both sides of the longitudinal seam Fig 7 18 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 The female end of each Z Vent III component has a silicone seal...

Page 28: ... 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 wide bead of high temperature silicone approximately inch from the male end of the pipe Also apply a bead of silicone along the first 2 of the longitudinal weld Insert the ma...

Page 29: ...al 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...

Page 30: ...st be installed as shown in Figure 21 A length of drain hose is supplied with the boiler and is connected to the trap as shown in Figure 21 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 21 b Condensate is sli...

Page 31: ...31 Figure 7 21 Condensate Piping Arrangement ...

Page 32: ...ed 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 ...

Page 33: ...T THOSE LISTED IN PART XI OF THIS MANUAL MAINTAIN THE PRESSURE IN THE BOILER AT A MINIMUM OF 12 PSI DESIGN SYSTEM TO ENSURE THAT THE FLOW FALLS WITHIN THE LIMITS CALLED FOR IN TABLE 9 1 B System Design Proper operation of the FCM boiler requires that the water flow through the boiler remain within the limits shown in Table 9 1 any time the burner is firing Failure to maintain the flow within these...

Page 34: ...e result is the total equivalent length of the secondary loop d Using 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 c 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 ...

Page 35: ...ves 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 ...

Page 36: ...36 Figure 9 3 Piping Method 1 Heat Indirect Water Heater Figure 9 4a Piping Method 1 Secondary Loop Piping Shaded ...

Page 37: ...37 Figure 9 4c Modular Boiler Piping Figure 9 4b Piping Method 1 Indirect Water Heater Loop Piping Shaded ...

Page 38: ...19SL Note 2 Taco 0013 Note 3 185 NOTES 1 Indirect water heaters with an asterisk will not achieve their catalog rating due to inadequate boiler output 2 When used with an indirect heater having a pressure drop less than 3 0 ft of head the Taco 0013 can be installed with up to 211 equivalent ft of 1 pipe 3 Use isolation relay between Taco 0013 and FCM see Figure 10 3 TABLE 9 5 PIPE AND CIRCULATOR S...

Page 39: ...tallations 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 ne...

Page 40: ...am 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 ...

Page 41: ...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 Syst...

Page 42: ...42 Figure 9 11 Chiller Piping Figure 9 10 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger ...

Page 43: ...e with the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 X Wiring CAUTION WHEN MAKING LOW VOLTAGE CONNECTIONS MAKE SURE THAT NO EXTERNAL POWER SOURCE IS PRESENT IN THE THERMOSTAT OR LIMIT CIRCUITS IF SUCH A POWER SOURCE IS PRESENT IT COULD DESTROY THE BOILER S MICROPROCESSOR CONTROL MCBA ONE EXAMPLE OF AN EXTERNAL POWER SOURCE T...

Page 44: ...44 Figure 10 1 Wiring Connections Diagram ...

Page 45: ...45 Figure 10 2 Ladder Diagram ...

Page 46: ...46 Figure 10 3 Wiring of Isolation Relay for Control of Two Heating Circulators ...

Page 47: ...formation on testing and purging gas lines 4 Vent system must be complete and free of obstructions before attempting to fire boiler Make sure that the silicone cure time called for in the vent assembly instructions has passed before firing boiler 5 Inspect all line voltage wiring for loose or uninsulated connections 6 Remove the dust cap from the condensate trap Fig 7 21 Add water to the trap unti...

Page 48: ...ating the boiler from the system with a heat exchanger Alternatively consider installing a water meter in the fill line to record additions of make up water Make sure that the expansion tank is properly sized and in good condition If it is not the relief valve may open frequently resulting in regular additions of make up water 3 Radiant Tubing and Oxygen Barriers g yg Even if the system is tight o...

Page 49: ...49 FCM Series Lighting and Operating Instructions ...

Page 50: ... Temp No call for heat After call for heat from heating thermostat 3 A SWT Self Check on Start up 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 Boiler responding to a call for heat 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 se...

Page 51: ...multaneously 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 bee...

Page 52: ...ns 13 Verify that the boiler starts and stops in response to calls for heat from the heating thermostat and indirect water heater thermostat Make sure that the appropriate circulators also start and stop in response to the thermostats 14 As shipped the heating and indirect water heater set point supply temperatures are both set to 180 F If necessary adjust these to the appropriate settings for the...

Page 53: ...fety 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 M...

Page 54: ...mbustion tests After 15 minutes the burner will automatically revert to modulation If it is desired to revert to modulation before 15 minutes has passed simultaneously pushing and will restore modulation In Parameter mode both set points can be changed and both zones turned on or off In addition both zones can be configured for continuous pump operation If the heating zone is set for continuous pu...

Page 55: ...55 FIGURE 12 2 BASIC MENU TREE ...

Page 56: ...e in Figure 12 4 The maximum set point is defined by parameter 4 factory set to 180 F when the outdoor temperature is 0 F or below The minimum set point temperature shown is 100 F when the outdoor temperature is 60 F or above As the outdoor temperature falls the supply water target temperature increases For example if the outdoor air temperature is 30 F the set point temperature for the supply wat...

Page 57: ... 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 bef...

Page 58: ...es to verify they are free from leaks Call the service technician to make repairs if required 4 Annual Inspections and Service In addition to the inspections listed above the following should be performed by a service technician once every year a Test the low water cutoff by pressing the Test button located at its end The yellow light should come on and E12 should flash on the display Push the res...

Page 59: ...nd 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 g001 Tc0 Tw 59 Tj eo6mbu6nyant lid Inspeve as...

Page 60: ...location Replace with 5A fuse provided Display reads U 125 continuously Fan running Defective AT250 transformer Blown F3 fuse in MCBA see Figure 13 2 for location Replace with 4A slow blow fuse provided Boiler not responding to call for heat Status code on display 0 see Figure 11 1 Boiler is not seeing call for heat Check thermostat or zone wiring for loose connection miswiring or defective thermo...

Page 61: ...s purged of air and that appropriate valves are open Sensor wiring reversed Supply or return sensor defective b 25 Supply water temperature has risen too quickly See possible causes for b18 Inadequate boiler water flow Verify that pump is operating and that pump and piping are sized per Part VIII of this manual b 26 Boiler safety limit or external limit wired across terminals 3 4 is open See possi...

Page 62: ... proper operation E 19 MCBA return sensor detected temperatures in excess of 200 F for an extended period of time See possible causes for b19 error E 28 Blower is not running when it should or fan speed signal not being detected by MCBA Loose connection in 120 VAC fan wiring Loose or miswired fan speed harness Defective fan E 29 Blower fan speed has not returned to zero rpm Miswired fan speed harn...

Page 63: ... 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 ...

Page 64: ...64 ...

Page 65: ... 01 1 16 Gauge Cap Tube Clamp 100377 01 1 100377 01 1 17 High Limit 100517 01 1 100517 01 1 18 Burner N A N A 101050 01 1 19 Burner Hood Gasket 100378 01 1 100378 01 1 20 5 x 8 Grooved Pin 100379 01 2 100379 01 2 21 Burner Hood FCM 100380 01 1 100380 01 1 22 Burner Hood Cover Plate Gasket 100381 01 1 100381 01 1 23 Burner Hood Cover Plate 100382 01 1 100382 01 1 24 M4 x 8 Machine Screw 100383 01 3...

Page 66: ...66 ...

Page 67: ...ng 12 101025 01 1 101025 01 1 72 Dungs Air Inlet Adaptor Part 2 male N A N A 101051 01 1 73 42 5mm Short Fan Adpator Plate N A N A 101052 01 1 74 M4 x 25mm Flat Head Machine Screw N A N A 101053 01 3 75 9mm Swirlplate Red N A N A 101054 01 1 76 Dungs Air Inlet Adaptor Part 1 female N A N A 101055 01 1 77 M4 x 10mm FH Machine Screw N A N A 101056 01 4 78 Injector Plate N A N A 101057 01 1 79 M4 x 2...

Page 68: ...68 ...

Page 69: ...69 ...

Page 70: ...70 ...

Page 71: ...2 01 4 100462 01 4 131 6 32 Wing Nut 101068 01 4 101068 01 4 132 Rubber Bumper 101069 01 2 101069 01 2 133 Pinhole Grommet 101070 01 2 101070 01 2 134 Draw Keeper 101071 01 2 101071 01 2 135 Bottom Panel 101072 01 1 101072 01 1 136 Bottom Pan Support Bracket 101073 01 1 101073 01 1 137 FCM Door Gasket 101074 01 1 101074 01 1 138 Upper Front Jacket Panel 101075 01 1 101075 01 1 139 U S Boiler Namep...

Page 72: ...72 150 151 152 153 154 155 ...

Page 73: ...73 156 157 158 159 160 161 ...

Page 74: ...74 162 ...

Page 75: ...75 NOTES ...

Page 76: ...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 3 SIGNAGE A ...

Page 77: ...nstructions 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 instru...

Page 78: ...78 NOTES ...

Page 79: ...79 NOTES ...

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