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I Product Description

The FCM090 and FCM120 are aluminum gas

fi

red condensing boilers designed for use in forced hot water heating

systems requiring supply water temperatures of 180°F or less. These boilers are designed for installation on a wall,
however they may be

fl

oor mounted using an optional pedestal kit available from U.S. Boiler Company, Inc. This

boiler may be vented vertically or horizontally with combustion air supplied from outdoors. This boiler is not
designed for use in gravity hot water systems or systems containing signi

fi

cant amounts of dissolved oxygen.

II Speci

fi

cations

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 suf

fi

x “N” for natural gas and “P” for propane. Ratings are the same for both fuels.

Using 60/100mm Concentric Vent System Supplied with the Boiler................................................................25 in.
Using Optional 60/100mm Concentric Vent Components ................................................................................18 ft
Using Approved 3” AL29-4C Horizontal Stainless Vent System and Optional Stainless Steel Vent Kit..........55 ft

See Vent Section for additional venting options and requirements

TABLE 2.3: MAXIMUM VENT LENGTHS

«
1
2
3
4
5
...
»

Содержание FREEDOM FCM120

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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 ...

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

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

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

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

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

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

Страница 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...

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

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

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 64: ...64 ...

Страница 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...

Страница 66: ...66 ...

Страница 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...

Страница 68: ...68 ...

Страница 69: ...69 ...

Страница 70: ...70 ...

Страница 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...

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

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

Страница 74: ...74 162 ...

Страница 75: ...75 NOTES ...

Страница 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 ...

Страница 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...

Страница 78: ...78 NOTES ...

Страница 79: ...79 NOTES ...

Страница 80: ......

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