Burnham Freedom Service manual

DNAGNITAREPO,NOITALLATSNI ROFSNOITCURTSNIECIVRES

™MODEERF

YCNEICIFFEHGIHGNISNEDNOC TNEVTCERID RELIOBRETAWTOHDERIF-SAG

WARNING:Improper installation, adjustment, alteration, service or maintenance can cause property damage,

injury, or loss of life. For assistance or additional information, consult a qualied installer, service agency or the

gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

101008-01R2-7/07

Table of Contents

I. Product Description............................................................................3

II. Specications .....................................................................................3

III. Before Installing..................................................................................4

IV. Locating The Boiler.............................................................................4

V. Mounting The Boiler ...........................................................................7

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

VII. Venting...............................................................................................12

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

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

C. Assembly of U.S. Boiler 60/100mm Concentric Venting ............ 23

D. Assembly of U.S. Boiler 80/125mm Concentric Venting ............27

E. Assembly of Stainless Steel Venting..........................................36

F. Condensate Trap and Drain .......................................................41

VIII. Gas Piping.........................................................................................43

IX. System Piping....................................................................................44

A. General System Piping Precautions...........................................44

B. System Design ...........................................................................44

C. Standard Piping Installation Requirements ................................ 51

D. Piping For Special Situations......................................................52

X. Wiring ................................................................................................54

XI. Start-up and Checkout.......................................................................58

XII. Operation...........................................................................................64

XIII. Service and Maintenance..................................................................69

XIV. Troubleshooting.................................................................................71

XV. Parts ................................................................................................74

Appendix A

Special Requirements For Side-Wall Vented

Appliances In The Commonwealth of Massachusetts..................86

Warranty.............................................................................Back Cover

I Product Description

TheFCM070,FCM090andFCM120arealuminumgas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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cantamountsofdissolvedoxygen.

II Speciﬁ cations

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)

FCM070 monoblock 70,000 30,000 63,000 55,000 95.4 0.41 102

FCM090 monoblock 90,000 30,000 80,000 70,000 94.5 0.41 102

FCM120 monoblock 120,000 40,000 107,000 93,000 95.2 0.62 110

*Addsuf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:

FCM070

.......................................................................................

32ft

FCM090

.......................................................................................

32ft

FCM120

.......................................................................................

18ft

UsingApproved3”AL29-4CHorizontalStainlessVentSystemandOptionalStainlessSteelVentKit..........55ft

SeeVentingSectionforadditionalventingoptionsandrequirements

TABLE 2.3: MAXIMUM VENT LENGTHS

TABLE 2.2: SPECIFICATIONS

Figure 2.1: General Con guration

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.

 •Whererequiredbytheauthorityhavingjurisdiction,thisinstallationmustconformtotheStandardfor 

 ControlsandSafetyDevicesforAutomaticallyFiredBoilers(ANSI/ASMECSD-1).

2) FCMboilersutilizealuminumheatexchangersconstructed,tested,andstampedinaccordancewithASMEBoilerand

PressureVesselCodeCase2382-2.SomejurisdictionswhichrequireASMEboilerconstructiondonotrecognizethis

CodeCaseandmaynotapprovetheinstallationofanaluminumboiler.Consulttheauthorityhavingjurisdictionbefore

installingthisboiler.

3) ReadSectionVIItoverifythatthemaximumcombustionairandexhaustpipelengthswillnotbeexceededinthe

plannedinstallation.AlsoverifythattheventterminalcanbelocatedinaccordancewithSectionVII.

4) Makesurethattheboileriscorrectlysized:

• Forheatingsystemsemployingconvectionradiation(baseboardorradiators),useanindustryacceptedsizing

methodsuchastheI=B=RHeatLossCalculationGuide(Pub.#H21or#H22)publishedbytheHydronicsInstitute

inBerkelyHeights,NJ.

• Fornewradiantheatingsystems,refertotheradianttubingmanufacturer’sboilersizingguidelines.

• ForsystemsincludingaAlliance™indirectwaterheater,sizetheboilertohaveeithertheDOEHeatingCapacity

requiredfortheAlliance™orthenetratingrequiredfortheheatingsystem,whicheverresultsinthelargerboiler.

• Forsystemsthatincorporateotherindirectwaterheaters,refertotheindirectwaterheatermanufacturer’s

instructionsforboileroutputrequirements.

5) Makesurethattheboilerreceivedisconguredforthecorrectgas(naturalorLP).

6) Makesurethattheboilerisconguredforuseatthealtitudeatwhichitistobeinstalled.

NOTICE

This product must be installed by a licensed plumber or gas tter when installed

within the Commonwealth of Massachusetts. See Appendix A for additional

important information about installing this product within the Commonwealth of

Massachusetts.

IV Locating the Boiler

1) ObservetheminimumclearancesshowninFigure4.1.Theseclearancesapplytobothcombustibleandnon-

combustiblematerials.ObservetheminimumclearancestocombustiblesforventpipeshowninTable4.2.

2) NotetherecommendedserviceclearancesinFigure4.1.Theseserviceclearancesarerecommended,butmayreduced

tothecombustibleclearancesprovided:

a. Accesstothefrontoftheboilerisprovidedthroughadoor

b. Accessisprovidedtothecondensatetrapandtransformerlocatedunderneaththeboiler.

3) Whentheboilerisinstalledontheoorusingtheoptionalpedestalkit,theboilermaybeinstalledonanon-carpeted

combustiblesurface.

4) Thereliefvalvemustbeinstalledinthefactoryspeciedlocation.

5) Theboilershouldbelocatedsoastominimizethelengthoftheventsystem.

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/

uorocarbons,paintremovers,cleaningsolventsanddetergents.

Figure 4.1: Clearances To Combustible Or Non-combustible Material

TABLE 4.2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION

TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE MINIMUM CLEARANCE

TO COMBUSTIBLE

MATERIAL

80/125 and 60/100mm

CONCENTRIC VENTING VERTICAL OR

HORIZONTAL ENCLOSED ON ALL FOUR SIDES 0”

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

METAL-FAB CORR/GUARD

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

METAL-FAB CORR/GUARD

HORIZONTAL OR VERTICAL

WITH OFFSETS ENCLOSED ON ALL FOUR SIDES 2-1/2”

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

METAL-FAB CORR/GUARD

VERTICAL WITH NO OFFSETS ENCLOSED ON ALL FOUR SIDES 2-1/2”

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  lled 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. Wall Mounting

1) Iftheboilerisinstalledonaframedwall,minimumacceptableframingis2x4studson16”centers.Theboiler

mountingholesareon16”centersforinstallationbetweentwostudsatthestandardspacing.Incaseswheretheboiler

cannotbecenteredbetweenthestuds,orwherethestudsarespacedcloserthan16”apart,theboilermaybeanchoredto

¾”plywoodorhorizontal2x4'sanchoredtothestuds.

2) 5/16”x2”lagscrewsandwashersareprovidedformountingthisboiler.Theselagscrewsareintendedformounting

theboilerdirectlyontostudscoveredwith½”sheetrock.Whentheboilerisattachedtoothertypesofconstruction,

suchasmasonry,usefastenerscapableofsupportingtheweightoftheboilerandattachedpipinginaccordancewith

goodconstructionpracticeandapplicablelocalcodes.

3) Makesurethatthesurfacetowhichtheboilerismountedisplumb.

4) Beforemountingtheboiler,makesurethat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modications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boilerishungonthewall.Ifthe5/16x2”lagscrewsareused,drill

3/16”pilotholes.

6) Cuttheopening/sinthewallfortheventsystem.Therecommendedholediameterforthestandard60/100mmcoaxial

ventpipeis4-3/8”.

7) Attachedthewallhanginghookusingthe5/16”x2”lagscrewsandwashers,orothersuitableanchorsasappropriate

(Figure5.2).Makesurethehookislevel.

8) HangtheboileronthewallhookasshowninFigure5.2.

9) IfnotalreadydoneinStep(4)locateanddrillholes“C”and“D”usingtheob-roundslotsinthebottommounting

ange.Securethebottomangetothewallusingthe5/16"x2”lagscrews,orotherfastenersasappropriate(Figure

5.2).

10)Verifythatthefrontoftheboilerisplumb.Ifitisnot,installwashersatholes“C”and“D”betweenthebottom

mountingangeandthewalltoadjust.

11) SeeSectionVII(“Venting)forinstructionsonattachingtheventsystemtotheboiler.

B. Floor Mounting

 ThisboilermaybemountedontheoorusinganoptionalpedestalkitavailablefromU.S.Boiler.Followthe

instructionsprovidedwiththiskittoassemblethepedestal,andattachittotheboiler.Whenthispedestalisused,the

boilermaybeinstalleddirectlyonanon-carpetedcombustibleoor.

Figure 5.1 Wall Mounting Hole Locations

Figure 5.2 Boiler Mounting/Hardware

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sufcientairforventilationmust

stillbeprovidedintheboilerroom.Airforventilationisrequiredtokeepvariousboilercomponentsfromoverheating

and is alwaysobtainedfromindoors.Toensureanadequateventilationairsupply,performthefollowingsteps:

Step1:Determinewhethertheboileristobeinstalledinaconnedspace-AconnedspaceisdenedbytheNational

FuelGasCodeashavingavolumelessthan50cubicfeetper1000BTU/hrinputofallappliancesinstalledinthat

space.Todeterminewhethertheboilerroomisaconnedspace:

• TotaltheinputofallappliancesintheboilerroominthousandsofBTU/hr.Roundtheresulttothenexthighest

1000BTU/hr.

• Findthevolumeoftheroomincubicfeet.Thevolumeoftheroomincubicfeetis:

 Length(ft)xwidth(ft)xceilingheight(ft)

 Incalculatingthevolumeoftheboilerroom,considerthevolumeofadjoiningspacesonlyifnodoorsare

installedbetweenthem.Ifdoorsareinstalledbetweentheboilerroomandanadjoiningspace,donotconsider

thevolumeoftheadjoiningspace,evenifthedoorisnormallyleftopen.

• DividethevolumeoftheboilerroombytheinputinthousandsofBTU/hr.Iftheresultislessthan50,theboiler

roomisaconned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connedspace.

Step2a:Iftheboileristobeplacedinaconnedspace,providetwoopeningsintotheboilerroom,oneneartheoorand

oneneartheceiling.Thetopedgeoftheupperopeningmustbewithin12”oftheceilingandthebottomedgeof

theloweropeningmustbewithin12”oftheoor(Figure6.1).Theminimumopeningdimensionis3inches.

• IftheFCMboileristheonlygas-burningapplianceintheboilerroom,theseopeningsmusteachhavea

minimumfreeareaof100squareinches.

• Ifothergas-burningappliancesareintheboilerroom,sizetheopeningsinaccordancewiththeappliance

manufacturer’sinstructionsortheNationalFuelGasCode.Minimumopeningfreeareais100squareinches

evenifopeningrequirementsforotherappliancesareless.

• Ifthetotalvolumeofboththeboilerroomandtheroomtowhichtheopeningsconnectislessthan50cubic

feetper1000BTU/hroftotalapplianceinput,installapairofidenticalopeningsintoathirdroom.Connect

additionalroomswithopeningsuntilthetotalvolumeofallroomsisatleast50cubicfeetper1000BTU/hrof

input.

• The“freearea”ofanopeningtakesintoaccounttheblockingeffectofmesh,grills,andlouvers.Wherescreens

areused,theymustbenonerthan¼”(4x4)mesh.

Step2b:Iftheboileristobeplacedinanunconnedspacethenaturalinltrationintotheboilerroomwillprovide

adequateairforventilationwithoutadditionalopeningsintoboilerroom.

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