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

2
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

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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

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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.

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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

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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”

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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.

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Figure 5.1 Wall Mounting Hole Locations

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Figure 5.2 Boiler Mounting/Hardware

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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.

11
Figure 6.1: Boiler Installed In A Conned Space, Ventilation Air From Inside

12
A. Vent System Design
Therearethreebasicwaystoventthisboiler:
• Horizontal (“Side Wall”) Concentric Venting-Vent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thespacebetweentheinnerandouterpipe.
• Horizontal (“Side Wall”) Twin Pipe Venting-Ventsystemexitsthebuildingthroughanoutsidewall.Combustion
airanduegasareroutedbetweentheboilerandoutdoorsusingseparatepipes.
• Vertical Concentric Venting-Ventsystemexitsthebuildingthroughtheroof.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
thespacebetweentheinnerandouterpipe.
• Vertical Twin Pipe Venting-Ventsystemexitsthebuildingthrougharoof.Combustionairanduegasarerouted
betweentheboilerandoutdoorsusingseparatepipes.
 Allofthesesystemsareconsidered“directvent”becauseinallofthem,airforcombustionisdrawndirectlyfromthe
outdoorsintotheboiler.AdescriptionofalloftheseventingoptionsareshowninTables7.1and7.9.Forclarity,these
ventoptionsarenumberedfrom1to6.OneoftheventoptioncolumnsinTables7.1or7.9mustmatchtheplanned
ventandairintakesystemexactly.Inaddition,observethefollowingguidelines:
1) Approvedventsystems-UseonlyoneoftheapprovedventsystemsshowninTables7.4a,7.4bor7.5.Thesevent
systemsfallintotwobasiccategories:
• Concentric Vent System-Thestandardboilerissuppliedwithaconcentricventsystemhavingamaximumusable
lengthof25”(Figure2.1).Forlongerruns,additionalstraightlengthsandelbowsareavailablefromU.S.Boiler.In
somecases,largerdiameterconcentricpipemustbeused.EachU.S.Boilerconcentricventcomponentconsistsofan
innerpipeofpolypropyleneandtheouterpipeofsteel.Integralgasketsoneachconcentricttingprovideagastight
seal.AlistofallU.S.BoilerconcentricventcomponentsisshowninTables7.4aor7.4b.
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aremadeofaspecialstainlesssteelalloy(AL29-4C)forprotection
againstcorrosiveuegascondensate.Theyaredesignedtoprovideagastightsealatalljointsandseamssothatue
gasdoesnotenterthebuilding.Eachapprovedventsystemhasauniquemethodforinstallation-do not attempt to
mix components from different vent systems.AlistofapprovedtwinpipeventsystemsisshowninTable7.5.Note
thataspecialventcollar(U.S.BoilerP/N101004-01)isrequirediftheboileristobeventedwithoneoftheapproved
stainlessventsystems.
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
Tables 7.4a or 7.4b.
* 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.
CAUTION
Moisture and ice may form on the surfaces around the vent termination. To prevent
deterioration, surfaces should be in good repair (sealed, painted, etc.)

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2) MaximumVentandAirIntakeLengths-Themaximumlengthoftheventairintakepipingdependsuponthevent
optionselectedandtheboilersize.SeeTable7.1or7.9forthemaximumventlength.Inhorizontalventsystems,the
lengthsshowninTable7.1areinadditiontotherststandardelbowontopoftheboiler.Forverticalventsystems,
themaximumverticalventlengthsshowninTable7.9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7.8 foreachadditionalelbowused.
Terminationttingsarenevercounted,althoughthelengthoftheconcentricterminalsection,includedwiththeboiler,is
counted.
Example:
A60/100mmconcentricventsystemisplannedforahorizontallyventedFCM120whichhasthefollowingcomponents:
80/125x60/100mmReducingElbow(suppliedwiththeboiler)
5ftStraightPipe.
90elbow
1½ftStraightPipe
45Elbow
UncutTerminalSection(suppliedwiththeboiler)
 TheVentOption#1columninTable7.1describesahorizontaldirectventsystemusing60/100mmconcentricventpipe.
Fromthiscolumn,weseethataFCM120mayhaveaventlengthofupto18ft.The90degreereducingelbowisnot
considered.Thelengthoftheterminalsection(notincludingtheplasticterminalitself)isapproximately221/2”(1.9
ft)installed.FromTable7.8,weseethattheequivalentlengthofthe60/100mmelbowis4.5ftandthattheequivalent
lengthofthe45degreeelbowis4ft.Thetotalequivalentlengthoftheplannedventingsystemistherefore:
 5ft(Straight)+4.5ft(90Elbow)+1.5ft(Straight)+4ft(45Elbow)+1.9ft(UncutTerminalSection)=16.9ft.
 SinceTable7.1showsamaximumallowableventlengthof18ft,theplannedventsystemlengthisacceptable.
3)MinimumVentandAirIntakeLengths-Observetheminimumventlengthsshownintables7.1and7.9.
4)PermittedTerminalsforHorizontalVenting:
• Vent Option 1-Theconcentric60/100mmconcentricventterminalissuppliedwiththeboileraspartofthestandard
ventsystem.
• Vent Option 2-TheexhaustterminalisU.S.Boilerpart8110701.Theairintakettingisa90degreeelbowwitha
rodentscreensuppliedbytheinstaller.Thiselbowismadeoutofthesamematerialastherestoftheairinletsystem
(eithergalvanizedorPVC)andisinstalledasshowninFigure7.3
• Vent Option 3 -Twoterminalsarepermitted:
a. 80/125mmConcentricVentTerminal(U.S.Boilerpart101494-01).
b. 80/125mmSnorkelTerminal(U.S.Boilerpart101544-01).Thisterminalallowstheventsystemtoexitthe
buildingclosetogradeandgouptheexteriorwallfarenoughtoprovideadequateclearancebetweentheterminal
itselfandthesnowline(seeFigure7.7).
5)HorizontalVentandAirIntakeTerminalLocation-Observethefollowinglimitationsontheventterminallocation(also
seeFigures7.6a,7.6b,7.6cand7.7).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inletintothebuilding.
• Fortwinpipeterminals,maintainthecorrectclearanceandorientationbetweentheventandairintaketerminals.
Theventandairintaketerminalsmustbeatthesameheightandtheircenterlinesmustbebetween12and36inches
apart.Bothterminalsmustbelocatedonthesamewall.
• Thebottomofallterminalsmustbeatleast12”abovethenormalsnowline.Innocaseshouldtheybelessthan12”
abovegradelevel.
• Thebottomoftheventterminalmustbeatleast7feetaboveapublicwalkway.
• Donotinstalltheventterminaldirectlyoverwindowsordoors.
• Thebottomoftheventterminalmustbeatleast3feetaboveanyforcedairinletlocatedwithin10feet.
• Aclearanceofatleast4feethorizontallymustbemaintainedbetweentheventterminalandgasmeters,electric
meters,regulators,andreliefequipment.Donotinstallventterminaloverthisequipment.
• Donotlocatetheventterminalunderdecksorsimilarstructures.
• Topofventterminalmustbeatleast5feetbeloweves,softs,oroverhangs.Maximumdepthofoverhangis3ft.

14
TABLE 7.1: SUMMARY OF HORIZONTAL VENTING OPTIONS
VENTOPTION# 123
CLASSIFICATIONUSEDINTHIS
MANUAL HORIZONTAL
CONCENTRIC HORIZONTAL TWINPIPE HORIZONTAL
CONCENTRIC
ILLUSTRATEDINFIGURE 7.2 7.3 7.2
VENTPIPEPENETRATION
THROUGHSTRUCTURE WALL WALL WALL
AIRINTAKEPIPEPENETRATION
THROUGHSTRUCTURE WALL WALL WALL
VENTPIPESIZE 60/100mm
CONCENTRIC
3” 80/125mm
CONCENTRIC
AIRINTAKEPIPESIZE 3”
MAXIMUMLENGTH
VENT
FCM070 32ft 55ft 55ft
FCM090 32ft 55ft 55ft
FCM120 18ft 55ft 55ft
INLET
FCM070 32ft 55ft 55ft
FCM090 32ft 55ft 55ft
FCM120 18ft 55ft 55ft
MINIMUMLENGTH
VENT
FCM070 10in 2ft 2ft
FCM090 10in 2ft 2ft
FCM120 10in 2ft 2ft
INLET
FCM070 10in 2ft 2ft
FCM090 10in 2ft 2ft
FCM120 10in 2ft 2ft
VENTTERMINAL 60/100mm
CONCENTRIC
P/N8110701 P/N101494-01
CONCENTRIC
orP/N101544-01
SNORKEL
AIRINTAKETERMINAL 3”90ELBOW
VENTMATERIAL
U.S.Boiler
60/100mmVENT
COMPONENTS
SHOWNIN
TABLE7.4a
(Note #1)
APPROVED
STAINLESS
STEELVENT
SYSTEMSHOWN
INTABLE7.5
U.S.Boiler
80/125mmVENT
COMPONENTS
SHOWNIN
TABLE7.4b
AIRINTAKEMATERIAL GALVANIZEDOR
PVC
Note #1: In Vent Option #1, the 80/125mm concentric straight section (P/N 101162-01) shown in Table 7.4a may be used
between the boiler and the rst 80/125 x 60/100 reducing elbow. If this is done, the overall maximum vent length is still
restricted to that shown for Vent Option #1 in Table 7.1 above.
HorizontalTerminalClearanceRequirements(Continued):
• Ventterminalmustbeatleast6feetfromaninsidecorner.
• Undercertainconditions,waterintheuegasmaycondense,andpossiblyfreeze,onobjectsaroundtheventterminal
includingonthestructureitself.Iftheseobjectsaresubjecttodamagebyuegascondensate,theyshouldbemovedor
protected.
• Ifpossible,installtheventandairintaketerminalsonawallawayfromtheprevailingwind.Reliableoperationofthis
boilercannotbeguaranteediftheseterminalsaresubjectedtowindsinexcessof40mph.
• Airintaketerminalmustnotterminateinareasthatmightcontaincombustionaircontaminates,suchasnearswimming
pools.SeeSectionIVfor moreinformationonpossiblecontaminates.

15
Figure 7.2: Horizontal Concentric Venting (Vent Options 1, 3)
Figure 7.3: Horizontal Twin Pipe Venting (Vent Option 2)

16
TABLE 7.4a: U.S. BOILER CONCENTRIC 60/100 VENT COMPONENTS (VENT OPTION 1)
PARTNO. DESCRIPTION SIZE USEDON VENT
OPTION# COMMENTS
101005-01 80/125x60/100mm
REDUCINGELBOW 80/125x
60/100mm 1INCLUDEDWITHSTANDARDBOILER
101006-01 TERMINALSECTION 60/100mm 1INCLUDEDWITHSTANDARDBOILER
101007-01 WALLGROMMET 60/100mm 1INCLUDEDWITHSTANDARDBOILER
101141-01 39”STRAIGHT 60/100mm 1OPTIONAL-MAYNOTBECUT
101140-01 78"STRAIGHT 60/100mm 1OPTIONAL-MAYNOTBECUT
101142-01 19-1/2”STRAIGHT 60/100mm 1OPTIONAL-CANBECUT
101144-01 90DEGREEELBOW 60/100mm 1OPTIONAL
101143-01 45DEGREEELBOW 60/100mm 1OPTIONAL
101162-01 39"STRAIGHT 80/125mm 1OPTIONAL-MAYNOTBECUT(Note #1)
101161-01 78"STRAIGHT 80/125 1OPTIONAL-MAYNOTBECUT
101167-01 19-1/2"STRAIGHT 80/125 2OPTIONAL-CANBECUT
Note #1: On60/100mmventsystems,thismayonlybeusedbetweentheboilerandtherst80/125x60/100ReducingElbow(seetext).
PARTNO. DESCRIPTION SIZE USEDON VENT
OPTION# COMMENTS
101490-01 90DEGREEEL(STANDARD) 80/125mm 3, 6
101542-01 90DEGREEEL(SWEEP) 80/125mm 3, 6
101491-01 45DEGREEEL 80/125mm 3, 6
101163-01 19-1/2”STRAIGHT 80/125mm 3, 6 CANBECUT
101162-01 39"STRAIGHT 80/125mm 3, 6 CANBECUT
101488-01 39”STRAIGHT 80/125mm 3, 6 MAYNOTBECUT
101161-01 78"STRAIGHT 80/125mm 3, 6 MAYNOTBECUT
101489-01 TELESCOPINGSTRAIGHT 80/125mm 3, 6 ADJUSTABLEFROM12-1/2"TO16-1/2"
101494-01 HORIZONTALTERMINAL 80/125mm 3
101544-01 SNORKELKIT 80/125mm 3(NOTE#1)
101495-01 VERTICALTERMINAL 80/125mm 6(NOTE#2)
101496-01 FLATROOFFLASHING 80/125mm 6
101543-01 SLOPEDROOFFLASHING 80/125mm 6(NOTE#3)
101492-01 SUPPORTELBOWWITH
CHIMNEYCHASEBRACKET 80/125mm 6(NOTE#4)
101498-01 SUPPORTBAND 80/125mm 3, 6
TABLE 7.4b: U.S. BOILER CONCENTRIC 80/125 VENT COMPONENTS (VENT OPTIONS 3, 6)
Notes: #1. SnorkelKitincludespartsneededtooffsetterminalonexteriorwallbyupto46".
#2.Verticalterminalcanbeusedwitheitheroftheroofashingslistedbeneathit.
#3.Slopedroofashingsuitableforroofanglesbetween25and45degrees.
#4.Usedatbaseofverticalruninsideunusedmasonrychinmey.

17
TABLE 7.5: PERMISSIBLE STAINLESS STEEL VENT SYSTEMS AND
PRINCIPLE VENT COMPONENTS (VENT OPTIONS 2, 5)
MANUFACTURER VENTSYSTEM SIZE COMPONENT PARTNUMBER
HEATFAB SAF-TVENT
EZSEAL
3BOILERCOLLAR 101004-01
3WALLTHIMBLE HEATFAB7393,7393GCS,5391CI
3HORIZONTALTERMINAL 8110701
3VERTICALTERMINAL HEATFAB9392
PROTECH
SYSTEMS
INC. FASNSEAL
3BOILERCOLLAR 101004-01
3WALLTHIMBLE FSWT3
3HORIZONTALTERMINAL 8110701
3VERTICALTERMINAL FSBS3
Z-FLEX SVE SERIESIII
(“Z-VENTIII”)
3BOILERCOLLAR 101004-01
3WALLTHIMBLE 2SVSWTEF03
3HORIZONTALTERMINAL 8110701
3VERTICALTERMINAL 24SVSTPF03
METAL-FAB CORR/GUARD
3BOILERCOLLAR 101004-01
3WALLTHIMBLE CGSWWPK(3")
3HORIZONTALTERMINAL 8110701
3VERTICALTERMINAL CGSWHTM(3")
NOTES:
1) Seeventsystemmanufacturer’sliteratureforotherpartnumbersthatarerequiredsuchasstraight
 pipe,elbows,restopsandventsupports.
2) PartNo.101004-01collarreplacesfactory-mountedconcentriccollar(Figure7.16).
6)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.Theairinletterminalconsistsofa180degreeelbow(ortwo90degreeelbows)witha
rodentscreenasshowninFigure7.10
• Vent Option 6-UseU.S.Boilerpart101495-01withtheappropriateashing(seeTable7.4b).
7)VerticalVentTerminalLocations(VentOptions5,6)-Observethefollowinglimitationsonthelocationofallverticalvent
terminals(seeFigures7.10and7.11):
• Thetopoftheventpipemustbeatleast2feetaboveanyobjectlocatedwithin10feet.
• ForVentOption#5,theverticaldistancebetweentopoftheventandairinletterminalopeningsmustbeat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terminalusedinVentOption#6hasaxeddistanceabovethestormcollarof19".Ifagreaterdistance
isneededtoprovidetheclearanceabovethesnowline,buildachaseontheroofandmounttheverticalterminalontop
ofthechase.
• ForVentOption#5,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inTable4.2orasrequiredbylocalcodes.Stainlessventmanufacturer’swallthimblepart
numbersareshowninTable7.5.Notethatconcentricventhasa"zero"clearancetocombustiblesandthereforedoesnot
requiretheuseofwallthimbles.

18
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

19
9) PitchofHorizontalPiping-Pitchallhorizontalpipingsothatanycondensatewhichformsinthepipingwillruntowards
theboiler:
• PitchU.S.Boilerhorizontalconcentricventing5/8”perfoot
• PitchStainlesssteelventing1/4”perfoot.
10)SupportingPipe-Verticalandhorizontalsectionsofpipemustbeproperlysupported:
• SupportU.S.Boilerconcentricventingnearthefemaleendofeachstraightsectionofpipe.
 Exception:Verticalrunsofconcentricpipeinanunusedchimney(Figure7.36)needonlybesupportedattheterminal
andatthebaseoftherun.
• Supportstainlesssteelventingascalledforbytheventmanufacturer’sinstructions.
Figure 7.7: Snorkel Terminal Conguration

20
TABLE 7.8: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH
VENTFITTING EQUIVALENTLENGTH(ft)
60/100mm90°CONCENTRICELBOW 4.5
60/100mm45°CONCENTRICELBOW 4.0
80/125mm90°CONCENTRICELBOW 8.5
80/125mm90°SWEEPCONCENTRICELBOW 5.5
80/125mm45°CONCENTRICELBOW 3.0
80/125mm90°CONCENTRICSUPPORTELBOW 8.5
3”SINGLEWALL90°ELBOW 5.5
3”SINGLEWALL45°ELBOW 4.0
TABLE 7.9: SUMMARY OF VERTICAL VENTING OPTIONS
VENT OPTION # 5 6
CLASSIFICATION USED IN THIS
MANUAL VERTICAL TWIN PIPE VERTICAL CONCENTRIC
ILLUSTRATED IN FIGURE 7.10 7.11
VENT PIPE PENETRATION
THROUGH STRUCTURE ROOF ROOF
AIR INTAKE PIPE STRUCTURE
THROUGH STRUCTURE ROOF ROOF
VENT PIPE SIZE 3" 80/125mm CONCENTRIC
AIR INTAKE PIPE SIZE 3"
MAXIMUM LENGTH
VENT
FCM070 49.5 ft. 49.5 ft.
FCM090 49.5 ft. 49.5 ft.
FCM120 49.5 ft. 49.5 ft.
INLET
FCM070 49.5 ft. 49.5 ft.
FCM090 49.5 ft. 49.5 ft.
FCM120 49.5 ft. 49.5 ft.
MINIMUM LENGTH
VENT
FCM070 2 ft. 2 ft.
FCM090 2 ft. 2 ft.
FCM120 2 ft. 2 ft.
INLET
FCM070 2 ft. 2 ft.
FCM090 2 ft. 2 ft.
FCM120 2 ft. 2 ft.
VENT TERMINAL STRAIGHT TERMINAL BY VENT
SYSTEM MFR. (TABLE 7.5) U.S. BOILER #101495-01
CONCENTRIC TERMINAL
(TABLE 7.4b)
AIR INTAKE TERMINAL 3" 180° ELBOW
(FIGURE 7.10)
VENT MATERIAL APPROVED STAINLESS STEEL
VENT SYSTEM U.S. BOILER 80/125mm
VENT COMPONENTS
SHOWN IN TABLE 7.4b.
AIR INTAKE MATERIAL GALVANIZED OR PVC