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Lexmark 321 Printer User Manual

1. E wot A ro 9 00 8 00 7 00 6 00 5 00 4 00 3 00 2 00 1 00 0 00 4 5 6 7 8 9 10 11 12 Figure 9 9 Boiler Head Loss FLOW GPM C Standard Piping Installation Requirements Observe the following guidelines when making the actual installation of the boiler piping 1 The relief valve is packaged loose with the boiler and must be installed in the location shown in Figure 2 1 The relief valve is set to open at 30 psi If the valve is replaced the replacement must have a relief capacity in excess of the DOE heating capacity for the boiler Pipe the discharge of the relief valve to a location where water or steam 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 where it is not likely to become plugged by debris DANGER PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION DO NOT INSTALL VALVE IN THE RELIEF VALVE DISCHARGE LINE DO NOT INSTALL RELIEF VALVE IN A LOCATION OTHER THAN THAT SPECIFIED BY THE FACTORY DO NOT PLUG THE RELIEF VALVE DISCHARGE 2 3 4 5 7 8 9 10 D 2 3 Circulator Required
2. 4 081 unejep jou 104 2 e Buipuodsei si u uA s Alddns 191064 3 6 Julod 19 e2ue19Je1 ISI WO Z 4 0 SI eunje1eduie 1oopino ay jurodjes Ajddns ayy s eanjejeduie siy si 105 5 100 y SO ON 0810 Jo 081 7 ejoN u YO Z JO 0 9uoZ MHA 08I H sjon u PIOH 330 P Yoyuo Joy WNL hhi P c 9 ON julod jes 16 E joy sous 330 gt 4 5 1 4 4 89 z 195 e2ue18jeo1 MHA 061 2 jeay 10 Buipuodsei1 Ajddns sous 5025 d3 s eiduexa s y Jo asn Ae ds q 3404 4315 shay Jo asn e1oN 1415504 uonduo seg Jdspweleg ejdurex3 Ae ds q ynsey uoyeing NOLLVIAHO 3NI 300 1 300 ASdNV1S 02 104 p ss 1d s ex ou Jayjo
3. suunjeJ el SIAOWN N33AAL38 3719901 OL 300M JSN 3381 ANSIA 9ISVA 2 11 ol 3 4 5 7 56 Two basic types of errors codes are shown on the display Soft Lockout Codes When a soft lockout occurs the boiler will shut down and the display will alternate between the number 9 and the letter b followed by a two digit service code A list of these codes and their meanings is shown in Table 14 3 The boiler will automatically restart once the condition that caused the lockout is corrected Hard Lockout Codes When a hard lockout occurs the boiler will shut down and the display will flash the letter E followed by a two digit service code A list of these codes and their meanings is shown in Table 14 4 Once the condition that caused the lockout is corrected the boiler will need to be manually reset using the RESET button on the display TABLE 12 3 BOILER STATUS CALI CN 0 Bumerof NocaMohemorDHW 6 Bumer ofi Set point temperature has been reached DHW ended 105 DHW post pump period Flashing Section to determine meaning of error code Burner on Held in high fire Burner on Held in low fire If an outdoor sensor is installed the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 12 4 The maximum set point is defined by parameter 4 factory
4. INVI 6 H HOLSISJY NHO AL HLUMONIG NOLLINOI MOSN3S 8 Mo WOSN3S HOOULRO S 1 3 1 16 1 DNLLYSH 1918 1 ONUV3H L Madii IA 9516 TVNIWH3L SOVL T0A TOALLNOD INTONSYO YEON THAASNOH ANNONO nenne BBBBBB I gt UND of dti j d 9 HO oy N of N 39VL OA INIT sj 1 39VLTOA INT rrogoz 489 5 a n HI OH SV SNV3W HOLMS 3014433 ONY LOANNOOSIC OVO REAO SOA Odd OLHITIVLSNI Se Sei eie EXE YALVIH LOSHIGNI Wa 7 n OOM OOF TIATIONCAH Van ees LL DOY LY SEIWSO SNVALL OOM dnd N 5 SNILV3H TALNI P PN
5. Cut the plastic inner pipe so that it will protrude 3 8 beyond the outer pipe when reinstalled in the outer pipe Use fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square De burr the cut edge of the plastic pipe with a file razor blade or fine sandpaper d Reinstall the inner pipe Dimension L 2 1 8 Mark To Cut Outer Pipe Retaining Tabs Concentric Terminal Section Figure 7 12 Cutting Outer Pipe Outer Pipe Plastic Cut Line For Inner Pipe Plastic Inner Pipe Figure 7 13 Cutting Inner Pipe 24 Wall Grommet E Insertion Mark __ Grommet Position Detail Figure 7 14 Preparing Terminal Section for Installation in the Wall Depth Gauge 10 x 1 2 Sheet Metal Screw 3 8 Exposed Drill i Drill 1 8 Hole 90 Concentric Reducing Elbow pet Outer Pipe Of Terminal Vent Section Wall Grommet Figure 7 15 Attaching Terminal Section D Assembly of Stainless Steel Venting CAUTION Vent systems made by Heat Fab Protech and Z Flex rely on gaskets for proper sealing When these vent systems are used take the following precautions Make sure that gasket is in position and undamaged in the female end of the pipe Make sure that both the male and female pipes are free of damage prior to assembly Only cut vent pipe as permit
6. 16 TABLE 7 4 U S BOILER CONCENTRIC VENT COMPONENTS VENT OPTION 1 USED PART NO DESCRIPTION SIZE VENT COMMENTS OPTION 80 125 x 60 100mm 80 125 x 101005 01 REDUCING ELBOW 60 100mm INCLUDED WITH STANDARD BOILER 101006 01 TERMINAL SECTION 60 100mm INCLUDED WITH STANDARD BOILER 101007 01 WALL GROMMET 60 100mm INCLUDED WITH STANDARD BOILER Note 1 On 60 100mm vent systems this may only be used between the boiler and the first 80 125 x 60 100 Reducing Elbow see text TABLE 7 5 PERMISSIBLE STAINLESS STEEL VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS VENT OPTIONS 2 5 MANUFACTURER VENT SYSTEM SIZE COMPONENT PART NUMBER BOILER COLLAR 101004 01 SART VENT WALL THIMBLE HEAT FAB 7393 7393GCS 5391 HEAT FAB EZ SEAL HORIZONTAL TERMINAL 8110701 VERTICAL TERMINAL HEAT FAB 9392 BOILER COLLAR 101004 01 a WALLTHIMBLE 3 U U O WALL THIMBLE FSWT SYSTEMS FASNSEAL pas INC HORIZONTAL TERMINAL 8110701 VERTICAL TERMINAL FSBS3 BOILER COLLAR 101004 01 3 SVE WALL THIMBLE 2SVSWTEFO3 SERIES III 3 HORIZONTAL TERMINAL 8110701 VERTICAL TERMINAL 24SVSTPFO3 BOILER COLLAR 101004 01 WALL THIMBLE SRO3WTI5 FLEX L INTL STAR 34 HORIZONTAL TERMINAL 8110701 VERTICAL TERMINAL SRTP 03 NOTES 1 See vent system manufacturer s literature for other part numbers that are required such as straight pipe elbows firestops and vent supports Z VENT 2 Part No 101004 01 collar replaces factory mounted co
7. 61 Trouble shooting problems where hard lockout code is displayed When hard lockout occurs the boiler will shut down and the display will flash the letter followed by a two digit service code Once the condition that caused the lockout is corrected the boiler will need to be manually reset using the RESET button on the display TABLE 14 4 HARD LOCKOUT CODES DISPLAYED CODE CONDITION POSSIBLE CAUSES A flame signal was present when there should Defective gas valve make sure inlet pressure is below maximum on rating plate be no flame before replacing valve gas pressure Gas pressure under minimum value shown on rating plate Gas line not completely purged of air Defective Electrode Flame failure after 5 tries to restart Loose burner ground connection Defective Ignition Cable Defective gas valve check for 24 VDC at harness during trial for ignition before replacing valve Air fuel mixture out of adjustment consult factory Loose or defective gas valve harness Check electrical connections Gas valve error Defective gas valve check for 24 VDC at harness during trial for ignition before replacing valve E Power failure occurred after lockout Some other error on this list occurred and power to the boiler was then interrupted Reset control and see if hard lockout reoccurs E05 E 06 E07 E11 If yellow light on LWCO is on system is low on water E12 Low water cut off circuit
8. h The female end of each Z Vent III component has a silicone sealing gasket Examine all vent components to insure that the gasket integrity has remained during shipping Gaskets must be in the proper position or flue gas could leak resulting in carbon monoxide poisoning 1 Align the second piece of pipe with the first and push them together as far as they will go but not less than 1 3 4 j Tighten gear clamp to a minimum torque of 40 in Ibs and a maximum of 50 in Ibs k 1 horizontal vent systems a locking band or gear clamp must be used at either side of the wall penetration to prevent shifting of the vent system in and out of the wall This applies to both combustible and non combustible walls Repeat Steps j for the remaining Z Vent III components n Allow the silicone to cure per the silicone manufacturer s instructions before operating the boiler LONGITUDINAL SEAM REPLACE AND REMOVE CLAMP BEFORE INSERTING PIPE Pan TIGHTEN CLAMP SMOOTH SILICONE OVER THIS JOINT UNASSEMBLED JOINT ASSEMBLED JOINT Figure 7 18 Z Vent Ill Connection to Vent Collar 27 5 Assembly of Heat Fab Saf T Vent EZ Seal a Saf T Vent General Notes These instructions cover the installation of Saf T Vent EZ Seal Saf T Vent EZ Seal piping has integral gaskets installed in the female ends of the pipe which seal the joints In general Saf T Vent pipe sections may not be cut Exceptions to this are the Saf T
9. 1 101048 01 2 101067 01 4 4 2 2 101070 01 100462 01 101068 01 101069 01 2 101071 01 1 101072 01 1 1 1 1 2 101077 01 101073 01 101074 01 101075 01 100846 01 2 101078 01 2 2 1 1 2 101083 01 101079 01 101080 01 101081 01 101082 01 2 101084 01 1 101085 01 1 101086 01 1 1 1 1 101089 01 101087 01 101088 01 100540 01 1 101090 01 1 101091 01 1 1 1 1 1 101096 01 101092 01 101093 01 101094 01 101095 01 120 1 100450 01 1 100452 01 4 100449 01 4 101031 01 4 1 1 1 100468 01 101032 01 101033 01 101034 01 1 101035 01 12 100423 01 8 101036 01 2 1 1 1 101040 01 101037 01 101038 01 101039 01 1 101041 01 2 2 101043 01 8 1 4 101046 01 101042 01 101044 01 101045 01 1 101047 01 1 101048 01 2 101067 01 4 4 2 2 101070 01 100462 01 101068 01 101069 01 2 101071 01 1 101072 01 1 1 1 1 2 101077 01 101073 01 101074 01 101075 01 100846 01 2 101078 01 2 2 101080 01 1 1 2 101083 01 101079 01 101081 01 101082 01 2 101084 01 1 101085 01 1 101086 01 1 1 1 1 101089 01 101087 01 101088 01 100540 01 1 101090 01 1 101091 01 1 1 1 1 1 101096 01 101092 01 101093 01 101094 01 101095 01 71 162 74 5 75 76 Appendix Special Require
10. Damage or malfunction due to the lack of required maintenance outlined in the Service and Maintenance section of the CHG FCM Installation and Operating Manual 6 Exclusive Remedy U S Boiler Company Inc obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties 7 Limitation of Damages Under no circumstances shall U S Boiler Company Service Charge No as 96 of 30 40 50 60 70 100 Charge Retail Price NOTE If the heat exchanger model involved is no longer available due to product obsolescence or redesign the value used to establish the retail price will be the published price as shown in the Burnham Hydronics Repair Parts Price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger ADDITIONAL TERMS AND CONDITIONS 1 Applicability The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to cast aluminum water boilers designated as residential grade by U S Boiler Company Inc and installed in a single or two family residence and do not apply to steam boilers of any kind or to commercial grade boilers 2 Components Manufactured by Others Upon expiration of the one year limited warranty on reside
11. 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 limits could result in erratic operation or premature boiler failure There are two basic methods that can be used to pipe the FCM boiler Method 1 is almost always preferred The instructions on the following pages describe these methods for piping FCM boilers and explain how to size the circulator and piping Additional information on hydronic system design may be found in Installation of Residential Hydronic Systems Pub 200 published by the Hydronics Institute in Berkeley Heights NJ TABLE 9 1 FLOW REQUIREMENTS THROUGH BOILER MIN em FLOW MAX FCM070 romo 40 o 120 33 2 3 34 Method 1 Primary Secondary Piping This method can be used in heat only applications as shown in Figure 9 2 or with an indirect water heater as shown in Figure 9 3 This method relies on primary secondary pumping to ensure that the required flow is always maintained through the boiler In this system the flow rate through the boiler is completely independent of the flow rate through the heating system Use the following guidelines to ensure that the boiler will have the required flow shown in Table 9 1 regardless of the flow in the heating system Primary Loop Piping Size the primary circu
12. 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 From System 5 Air Separator amp Air Vent Automatic Fill Valve Cold Water Line To System lt Central Heating Central Heating Secondary Primary Circulator Circulator Expansion Tank Isolation sk Valves Figure 9 2 Piping Method 1 Heat Only 35 36 From System Air Separator amp Air Vent Automatic Fill Valve Cold Water Line To System ES Central Heating Primary Circulator Boiler Supply Connection Boiler Return Connection Circulator Swing Check Valve Indirect Domestic Water Heater IWH Figure 9 3 Piping Method 1 Heat Indirect Water Heater From System er Air Separator amp Air Vent Automatic Fill Valve Cold Water Line To System Central Heating Primary Circulator Boiler Supply Connection Boiler Return Connection Circulator Swing Check Valve Se Lu Indirect Domestic Water Heater IWH Figure 9 4a Piping Method 1 Secondary Loop Piping Shaded From System SER To System bra Central Heating Primary Circulator Tun Central Heating Secondary Expansion Circulator Boiler Supply Tank Connection Boiler Return Conne
13. Connections 4 Assembly of Z Flex Z Vent a General Notes Non expanded ends of SVE Series III piping sections may be cut using aviation snips or a 24 thread per inch hacksaw File or sand the cut end smooth before assembling Expanded ends may be cut to adapt the SVE series III to the vent collar See the following instructions Support horizontal piping sections at intervals of 48 or less Vertical venting systems must be supported by at least one Z Flex fire stop An additional vertical support is required after any offset and as required by the Z Vent III installation instructions b Start assembly of the vent system at the boiler Remove the hose clamp shipped on the FCM vent collar Bend the three hose clamp tabs on this collar outward slightly Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler Remove dirt grease and moisture from the surfaces to be sealed Dry surfaces or allow to dry thoroughly d On the male end of the pipe apply a 4 wide bead of high temperature silicone approximately Y inch from the male end of the pipe Apply 14 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
14. Figure 10 2 Ladder Diagram IGNITION ELECTRODE 15 000 VOLTS 45 LINE VOLTAGE FACTORY WIRING LINE VOLTAGE FIELD WIRING L1 POWER SUPPLY FIELD INSTALLER L2 120 6071 SUPPLIED RELAY 120 VAC COIL HEATING CIRCULATOR 2 120 COIL HEATING INDIRECT CIRCULATOR WATER HEATER IF USED Figure 10 3 Wiring of Isolation Relay for Control of Two Heating Circulators 46 Start up Checkout SAFE LIGHTING AND OTHER PERFORMANCE CRITERIA WERE WITH THE GAS TRAIN ASSEMBLY PROVIDED ON THE BOILER WHEN THE BOILER UNDERWENT THE TEST SPECIFIED IN Z21 13 Use the following procedure for initial start up of the boiler 1 If not already done flush the system to remove sediment flux and traces of boiler additives This should be done with the boiler isolated from the system 2 Fill the boiler and hydronic system with water meeting the following requirements below also see the note on the next page pH between 6 5 and 8 5 Total Solids less than 2500 PPM Hardness less than 120 PPM 7 Grains Gallon Pressurize the system to at least 12 psi at the boiler WARNING NEVER ATTEMPT TO FILL A HOT EMPTY BOILER 3 Check all new piping for leaks and purge piping sections that are filled with air See the National Fuel Gas Code for additional information on testing and purging gas lines WARNING NEVER USE FLA
15. MOLOSNNOO HO TOBWAS INTIVAINOS SLI NMOHS WS HUM T39V EY 38 18 G3OV 38 Len HL HUM Cal Idd 18 TVNIOIHO HL JO dl LON HOLIMS MnsSdHd 007 NOLLYWISNI 22 1 HIA 6 2 46 IAAL SMY 2215 ONNONO 4 E 0 05 HOLINDI 2 NIM INANV MGLL HO ML SMY 3218 ONIN 0 501 SHUA CHONVHLS IAAL GL 1216 ANOLOVA QN393134dAL SHIM 44 POWER SUPPLY 1207 6071 SENSING CIRCUIT COMBUSTION BLOWER 120 FUSE HEATING CIRCULATOR CN AA AA INDIRECT WATER HEATER IWH CIRCULATOR Oo MCBA TRANSFORMER AT250A READ FLAME SIGNAL IN VOLTS DC BETWEEN TERMINAL 8 AND GROUND MCBA LOW VOLTAGE INTERNAL CIRCUITRY ADDITIONAL LIMIT r SUPPLY WATER TEMP SENSOR X3 1 DEETAN RETURN WATER TEMP SENSOR DHW THERMOSTAT WHEN USED OUTDOOR SENSOR WHEN USED SPEED CONTROL CIRCUITS DISPLAY E 120 VAC WIRING LOW VOLTAGE WIRING IGNITOR SENSOR WIRING
16. OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL CAST ALUMINUM GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR A MAXIMUM OF FIFTEEN YEARS AT THE ORIGINAL PLACE OF INSTALLATION SOME STATES DO NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty service the owner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler although failure to comply with this request will not void the owner s rights under these warranties Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties the owner should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the owner should write to U S Boiler Company Inc Burnham Hydronics at Box 3079 Lancaster 17604 giving full particulars in support of the claim The owner is required to make available for inspection by U S Boiler Company Inc or its representative the parts claimed to be defective and if requested by U S Boiler Company Inc to ship these parts prepaid to U S Boiler Company Inc at the above address for inspection or repair In addition the owner agrees to make all reasonable efforts to settle
17. S Boiler If either of the above antifreezes are used test the boiler water on an annual basis to ensure that the antifreeze remains non corrosive This is done with Fernox test kit I TK available from U S Boiler Other Antifreezes and Boiler Additives Do not add other additives unless they are specifically approved in wiring by U S Boiler for use with this boiler This includes other aluminum safe antifreezes System PH Maintain the PH in the system between 6 5 and 8 5 FCM Series Lighting and Operating Instructions FOR YOUR SAFETY READ BEFORE LIGHTING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control knob Never use tools If the knob wi
18. Vent slip connector and connections to the boiler vent collar In these cases use a sharp pair of aviation snips an abrasive cut off or a plasma cutter See the Saf T Vent instructions for information on cutting the slip connector Orient Saf T Vent components so that the arrows on the piping labels are in the direction of flue gas flow Support horizontal piping sections at intervals of 6 feet or less Vertical venting systems must be supported by at least one Heat Fab support An additional vertical support is required after any offset b Connection to Boiler Start assembly of the vent system at the boiler Remove the hose clamp shipped on the FCM vent collar Bend the three hose clamp tabs on this collar outward slightly Cut the male spigot off of the first piece of pipe Fig 7 19 If necessary crimp the cut end of the 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 4 wide bead of high temperature silicone approximately inch from the male end of the pipe Also apply a 4 bead of silicone along the first 2 V2 of the longitudinal weld Insert the male end of the pipe into the boiler vent collar until it bottoms out Apply an additional bead of silicone over the outside of the joint and smooth out Fig 7 19 Replace and tighten the clam
19. and 6 the boiler will adjust the target space heating set point supply water temperature downwards as the outdoor air temperature increases If used this sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house Avoid placing this sensor in areas where it may be covered with ice or snow In general locations where the sensor will pick up direct radiation from the sun should also be avoided Avoid placing the sensor near potential sources of electrical noise such as transformers power lines and fluorescent lighting Wire the sensor to the boiler using 22 gauge or larger wire As with the sensor the sensor wiring should be routed away from sources of electrical noise Where it is impossible to avoid such noise sources wire the sensor using 2 conductor UL Type AWM Style 2092 300Volt 60 C shielded cable Connect one end of the shielding on this cable to ground 43 suonoeuuo 1 01 A T S S CON HLIM 300419373 NOLLINOI HOSN3S YOSNIS AWISIO TYAN a TEMASNOH I NOLSISTN anu N WHO 022 Nun Aldans I_ B
20. any dust or lint from the burner If the burner shows signs of deterioration or corrosion replace it immediately Inspect the burner gasket and replace if necessary Inspect the heat exchanger and vacuum any debris found on the pins and other surfaces Clean the casting pins by flushing with clean water A soft nylon brush may be used in accessible areas Drain and flush the inside of the heat exchanger and condensate collector as required Do not use any cleaning agents or solvents Inspect the condensate trap to verify it is open and free from debris Clean if necessary Reinstall the burner burner hood and fan gas valve assembly Reconnect any wiring which has been disconnected Inspect the heating system and correct any other deficiencies prior to restarting the boiler Follow Section XI Start up and Checkout instructions before leaving installation Perform the combustion test outlined in Section XI Verify that the system PH is between 6 5 and 8 5 Check for vent terminal obstructions and clean as necessary 59 XIV Troubleshooting WARNING Turn off power to boiler before replacing fuses or working on wiring A Troubleshooting problems where no error code is displayed TABLE 14 1 NO ERROR CODE DISPLAYED CONDITION POSSIBLE CAUSES Display Blank Fan off LWCO lights off nn Power at boiler Check breaker and wiring between breaker panel Loose 120VAC connection wiring between boiler J Box a
21. 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 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 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 8 350 ft 350 150 z 2 33 Since 2 33 is less than 50 the boiler room is a confined space Step 2a If the boiler is to be placed in a confined space provide two openings into the boiler room one near the floor 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 floor Fig 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
22. each have a minimum free area of 100 square inches If other gas burning appliances 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 e 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 finer than 4 x 4 mesh Step 2b If the boiler is to be placed in an unconfined space the natural infiltration into the boiler room will provide adequate air for ventilation without additional openings into boiler room 10 UPPER OPENING SEE TEXT FOR BOILER OPENING SIZE ROOM LOWER OPENING Figure 6 1 Boiler Installed In A Confined Space Ventilation Air From Inside 11 1 2 12 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 bo
23. error was far below the minimum firing rate of the boiler Defective primary pump or no flow in primary loop Piping Method 1 Control system miswired so that boiler operation is permitted when no zones are calling MCBA supply sensor detected temperatures in excess MCBA return sensor detected temperatures in excess See possible causes for b18 of 200 F Flow through boiler reversed Sensor wiring reversed Flow through boiler reversed Verify correct piping and pump orientation MCBA is reading a return sensor temperature higher No boiler water flow Verify that system is purged of air and that than the supply sensor temperature Condition must be appropriate valves are open present for at least 75s for this error code to appear Sensor wiring reversed Supply or return sensor defective 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 Inadequate boiler water flow Verify that pump is operating and that pump and piping are sized per Part VIII of this manual Blockage in pressure switch hose Pressure switch wires shorted together Pressure switch circuit closed with fan off Defective pressure switch e Loose or miswired fan speed harness if b61 error code is observed while fan is running b 65 Fan is not achieving set point speed Loose or incorrect fan speed control connection Defective fan
24. 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 filled 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 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 34 plywood or horizontal 2 x 4 s anchored to the studs 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 1 2 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 Make sure that the surface to which the boiler is mounted is plumb 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 Once a suitable location has been
25. open If neither yellow nor green light is on check LWCO harness and check for 24VAC across AT140 transformer E 00 E 02 E 03 04 Internal control failure Reset the control If problem reoccurs replace the MCBA Internal control failure Reset the control If problem reoccurs replace the MCBA MCBA supply sensor detected temperatures in excess of 200 F for an extended period of time See possible causes for b18 error Also check safety limit for proper operation MCBA return sensor detected temperatures in excess of 200 F for an extended period of time Seg possible Loose connection 120 fan wiring Loose or miswired fan speed harness Defective fan Defective supply sensor 2 Blower is not running when it should or fan speed signal not being detected by MCBA Supply water temperature sensor circuit open Loose ormiewired s pply sensar wiring P p Defective supply sensor Return water temperature sensor circuit open ES er HEBEN rA seneo Wiig p Defective return sensor File das temperat re sensor cireuk wean Loose or miswired flue temp sensor wiring 9 p P Defective flue temp sensor Internal control failure Reset the control If problem reoccurs replace the MCBA Heat exchanger needs to be cleaned Flue gas temperature over 230 F Boiler over fired Air fuel mixture out of adjustment consult factory Internal control failure Reset t
26. operate follow the instructions To Turn Off Gas To Appliance below and call your service technician or gas supplier Replace the upper boiler access panel and the front door panel TO TURN OFF GAS TO THE APPLIANCE 1 Turn off all electric power to the appliance if service is to be performed 2 Setthe thermostat to the lowest setting 3 Turn the external boiler manual gas valve T x handle clockwise to close the gas supply 4 Replace the upper boiler access panel and the front door panel 49 7 Start the boiler using the lighting instructions on page 49 After the boiler is powered up it should go through the following sequence Sequence Display Meaning 1 9 125 or Blank Checking internal software power up only 2 0 6 Boiler in standby 54 7 Supply Water Temp No call for heat After call for heat from heating thermostat 3 ASWT Self Check on Start up 4 5 507 Blower circulator on Checking for adequate air flow 5 Lowy Prepurge 6 2 5 Trial for ignition 7 3 5wT 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 several tries for ignition before a flame is established If more than 5 tries for ignition are needed it will be necessary to press the reset button to restart the boiler Once a flame has been established for the first time subsequ
27. plastic terminal itself is approximately 22 1 2 1 9 ft installed From Table 7 7 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 Lensths Observe the minimum vent lengths shown in tables 7 1 and 7 8 4 5 Permitted Terminals for Horizontal Venting Vent Option 1 The 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 fitting is 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 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 inlet into the building For twin pip
28. set to 180 F when the outdoor temperature is O 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 water is 140 F An indirect water heater thermostat can be connected between terminals 7 and 8 on the terminal strip When this thermostat closes the central heating circulator will be turned off and the DHW circulator will be turned on An external limit control can be installed between terminals 3 and 4 on the terminal strip Be sure to remove the jumper between terminals 3 and 4 when adding an external limit control to the system If the external limit opens the boiler will shut down and error code b 26 will be displayed If the limit installed is a manual reset type it will need to be reset before the boiler will operate The sequence of operation for a FCM series boiler on a call for heat from a thermostat is as described below a When power is first turned on 120V is provided to the MCBA the combustion fan and the LWCO transformer A separate 5 transformer connected directly to the MCBA powers all other low voltage circuits b For the first few seconds after power up the control module goes through a self check When there is a call for heat the control module checks to make sure the air pre
29. 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 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 Support stainless steel venting as called for by the vent manufacturer s instructions TABLE 7 8 SUMMARY OF VERTICAL VENTING OPTIONS CLASSIFICATION USED IN THIS VERTICAL RESERVED FOR MANUAL TWIN PIPE FUTURE USE STRAIGHT TERMINAL VENT TERMINAL BY VENT SYSTEM MFR TABLE 7 5 3 180 ELBOW AIR INTAKE TERMINAL IUO FIGURE 79 APPROVED STAINLESS VENT MATERIAL STEEL VENT SYSTEM SHOWN IN TABLE 7 5 AIR INTAKE MATERIAL GALVANIZED OR PVC MAXIMUM LENGTH MINIMUM LENGTH 19 Figure 7 9 Vertical Twin Pipe Vent System Vent Option 5 Removing an Existing Boiler From a Common Chimney Read this only if the FCM boiler is replacing an existing boiler that is being removed from a common chimney This section does not apply to the installation of a FCM boiler In some cases when an existing boil
30. 100539 0 1 100398 0 1 100399 0 o 1 01 1 100429 0 36 1010 1 1010 1 1010 1 1010 1 1010 1 10101 12 0 o 1 a o o o 7 01 1 100456 0 1 1010 1 1010 1 1 101020 0 o o 100486 0 4 101021 0 1 101022 0 1 1 1 101052 0 3 101053 0 1 101054 01 1 101023 0 1 101024 0 1 101025 0 1 101051 0 1 101055 0 4 1 101057 0 4 101056 0 3 101058 0 1 101059 0 1 101060 01 1 101061 0 6 1 101062 0 100462 0 1 101063 0 2 101064 0 1 1 1 101029 0 1 101026 0 1 101065 0 1 101027 0 1 101028 0 1 100471 0 1 100466 0 1 100467 0 1 2 1 100474 0 1 101030 0 2 100424 0 8 100463 0 1 101066 0 1 100469 0 70 02 3 22 23 24 25 26 27 28 29 30 31 32 wlj S On o oo gt N a a N PARTS LIST Continued DESCRIPTION DISP4D Graphic Overlay Mounting Plate 8 32 Lock Nut Zinc Plated Brass Spacer 8 32 x 34 Round Head Machine Screw 8 32 x Ye PH Machine Screw 8 32 Hex Nut Resistor Clamp Rear Panel 10 x Truss Hd Screws 1 8 Aluminum Pop Rivet Draw Latch Kennard 1110 Grommet Top Panel Vent Stub Wall Hook 5 16 5 16 x 2 Lag Screw Flat Washe
31. 51 01 42 5mm Short Fan Adpator Plate 1 101052 01 0 9mm Swirlplate Red 5mm Swirlplate Blue 0 0 75 M4 x 25mm Positdrive Hd Screws 3 058 01 so 15x 17mm O Ring 1 101059 01 5 0mm Orifice 1 101167 01 6 32 x Ya HWH Type F Self Tapping Screw 6 100462 01 Ha cn ren ATT 0 0 0 81 e em wass E suena a 10 32 x 3 8 Ground Screw 1 101030 01 sing ere es _ Te Part Number Quantity 090 1 100396 0 2 100397 0 1 1010 1 1010 1 10042 36 1010 1 1010 1010 1 1010 1 1010 1 10101 1 100539 0 1 100398 0 1 100399 0 0 0 1 01 o 12 0 3 0 T 1 4 0 a o o o 7 01 1 100456 0 1 1010 1 1010 1 1 101020 0 8 0 o 100486 0 4 101021 0 1 101022 0 1 101023 0 1 101052 0 1 101024 0 1 101025 0 1 101051 0 3 101053 0 1 101166 01 1 101057 0 1 101055 0 4 101056 0 3 101058 0 1 101059 0 1 101167 01 1 101061 0 6 100462 0 1 101062 0 1 101063 0 2 101064 0 1 101026 0 1 101029 0 1 101065 0 1 101027 0 1 101028 0 1 100471 0 1 100474 0 1 100466 0 1 100467 0 1 101030 0 2 100424 0 8 100463 0 1 101066 0 1 100469 0 120 1 100396 0 2 100397 0 1 1 1 1 1010 1 1010 1
32. 60 100mm terminal section straight section with a terminal and overall length of 27 3 4 P N 101006 01 c 2 Rubber wall grommets P N 101007 01 2 Unless the 80 125 straight riser P N 101163 01 is used start by attaching the reducing elbow to the boiler collar To do so remove the clamp from the large end of the reducing elbow and set aside Apply a small amount of water to the brown gasket on the boiler collar Push the elbow onto the boiler collar until the bead on the elbow contacts the top edge of the collar Figure 7 10 3 Reinstall the clamp removed in Step 2 so that the elbow is secured to the boiler collar 4 Ifno additional sections of concentric pipe are required attach the terminal section to the elbow In most cases it will need to be cut before doing so Use the following procedure to cut the pipe a Measure distance L from the outside surface of the exterior wall to the end of the elbow as shown in Figure 7 11 b Add 2 1 8 to distance L Carefully mark this length on the pipe as shown in Figure 7 12 C Press in the two tabs holding the plastic terminal in the terminal section Figure 7 12 Carefully pull out the terminal and the inner pipe d 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 e Cut the plastic inner pipe so that it will pr
33. 65 01 00366 01 00520 01 00499 01 00367 01 00369 01 00363 01 00370 01 00376 01 00377 01 00517 01 01165 01 00378 01 00379 01 00380 01 00381 01 00382 01 00383 01 00384 01 00497 01 00385 01 00510 01 00509 01 00386 01 00387 01 00493 01 00506 01 00508 01 00507 01 00388 01 00389 01 00390 01 00391 01 00392 01 00393 01 00394 01 00395 01 Quantity Part Number FCM120 1 100362 01 00487 01 100364 01 00542 01 00537 01 00536 01 00368 01 00453 01 00542 01 4 100371 01 00372 01 01049 01 00373 01 00374 01 00375 01 00365 01 00366 01 00520 01 00499 01 00367 01 00369 01 00363 01 00370 01 00376 01 100377 01 00517 01 01050 01 00378 01 00379 01 00380 01 00381 01 100382 01 00383 01 00384 01 s s 00497 01 00385 01 00510 01 00509 01 00386 01 00387 01 00493 01 00506 01 00508 01 00507 01 00388 01 00389 01 00390 01 00391 01 00392 01 00393 01 00394 01 00395 01 66 PARTS LIST Continued DESCRIPTION 6 V x 11 Yellow Coated CSST Nut by Nut 5 8 OD x 1 2 CSST Adaptor 2 1 2 Blk Elbow 1 100539 01 10 x Ye Sheet Metal Screw 36 101012 01 e ar BE SRL anna oa 0 0 0 070 1 100396 01 00397 01 __69 Fan inlet Block 1 101023 01 10 32 x 1 8 ID Hose Barb 1 101024 01 1 8 ID Silicone Tubing 12 1 101025 01 Dungs Air Inlet Adaptor Part 2 male 1 1010
34. ALTOSL 9 Taco 0014 50 AL119SL AL27SL AL35SL ALSOSL AL7OSL ALI19SL AL27SL AL35SL ALSOSL Taco 0014 71 AL70SL AL119SL AL27SL AL35SL ALSOSL AL70SL 11991 0014 45 Note 2 AL27SL AL35SL ALSOSL AL70SL AL119SL Note 2 in NPT ft HEAD Taco 0013 Note 3 Taco 0013 Note 3 NOTES 2 3 M D Indirect water heaters with an asterisk will not achieve their catalog rating due to inadequate boiler water flow and or inadequate boiler output 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 Use isolation relay between Taco 0013 and FCM see Figure 10 3 TABLE 9 7 FITTING EQUIVALENT LENGTHS FITTING PIPE SIZE EQUIVALENT LENGTH ft A Method 2 Direct Connection to Heating System Generally NOT Recommended The FCM can be connected directly to the heating system as is done with conventional boilers Figure 9 8 If this is done the flow rate through the boiler will equal the flow rate through the system The flow rate through the system must therefore always remain within the limits shown in Table 9 1 For this reason the pressure drop through the entire system must be known added to the boiler pressure drop and a circulator selected which will provide the required flow at the total calculated pressure drop This method is generally not
35. C intake system components c If galvanized piping is used use at least two sheet metal screws per joint Seal the outside of all joints d 3 galvanized smoke pipe will fit inside the inlet collar on the boiler Depending upon the exact OD of the pipe used e wm f it may be necessary to crimp this pipe Secure with a single 10 sheet metal screw through the hole in the inlet collar and seal the outside of the joint with silicone If PVC is used for the intake system use a short piece of 3 galvanized pipe to connect the PVC to the boiler Silicone the outside of the joint between the PVC and galvanized pipe Horizontal intake terminal is a 90 degree elbow pointing down Elbow should protrude the same distance from the wall as the exhaust terminal Vertical air intake terminal consists of a 180 degree bend composed of two 90 degree elbows as shown in Figure 7 9 g Install a rodent screen not supplied in the inlet terminal Use a screen having 1 2 2 x 2 or larger mesh E Condensate Trap and Drain Line condensate which forms in the boiler or vent system collects in the sump under the heat exchanger and leaves the boiler through the condensate trap This trap allows condensate to drain from the sump while retaining flue gases in the boiler The trap is supplied loose and must 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 t
36. CHECKOUL VR RO RAS edocs 47 OPI EEE ee 53 Service and 58 iss suet da a 60 allo us naar 63 Appendix A Special Requirements For Side Wall Vented Appliances In The Commonwealth of Massachusetts 76 A DS A AAA IA an Back Cover I Product Description The 070 090 and 120 aluminum gas fired 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 floor 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 significant amounts of dissolved oxygen Specifications See Table 2 3 7414 Sealing Inside Grommet Standard Of Wall Vent p Relief Valve 3 ins N Supply Water Connection 31 1 2 Temperature Control Pressure Gauge Access Viewport d Panel Drain Valve 138 Gas Connection 17 78 Outside Left View Front View Return Water Of Wall Figure 2 1 General Configuration Connection TABLE 2 2 SPECIFICATIONS NO OF MAXIMUM MINIMUM WATER E MODEL SE ONS INPUT INPUT CAPACIT
37. EARANCES TOP 12 5 8 FRONT 24 BOTTOM 24 THESE SERVICE CLEARANCES RECOMMENDED BUT MAY BE REDUCED TO THE COMBUSTIBLE CLEARANCES PROVIDED 1 ACCESS TO THE FRONT OF THE BOILER IS PROVIDED THROUGH A DOOR 2 ACCESS 5 PROVIDED TO THE CONDENSATE TRAP AND TRANSFORMER LOCATED UNDERNEATH THE BOILER NOTE WHEN BOILER IS VENTED VERTICALLY THE MINIMUM CLEARANCE FROM THE TOP OF THE JACKET CAN BE REDUCED TO 7 1 2 Provide Access To This Area T For Inspection Of Condensate Right View Trap amp Transformer Figure 4 1 Clearances To Combustible Or Non combustible Material TABLE 4 2 CLEARANCES FROM VENT PIPING COMBUSTIBLE CONSTRUCTION MINIMUM CLEARANCE TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE TO COMBUSTIBLE MATERIAL 60 100mm VERTICAL OR eure ENCLOSED ON ALL FOUR SIDES HEAT FAB SAF T VENT PROTECH FASNSEAL VERTICAL OR BUS on 1 Z FLEX Z VENT III HORIZONTAL FLEX L STAR 34 MAXIMUM OF THREE SIDES HEAT FAB SAF T VENT PROTECH FASNSEAL HORIZONTAL OR VERTICAL 2 1 2 Z FLEX Z VENT Ill WITH OFFSETS ENG OPEROR a SIRES FLEX L STAR 34 HEAT FAB SAF T VENT PROTECH FASNSEAL 2 1 2 Z FLEX Z VENT Il VERTICAL WITH NO OFFSETS ENCLOSED ON ALL FOUR SIDES FLEX L STAR 34 1 2 3 4 5 7 8 9 V Mounting The Boiler CAUTION This boiler weighs approximately 110 pounds Two people are required to safely lift this boiler
38. EXXXXXXXX SMOOTH SILICONE OVER THIS JOINT UNASSEMBLED JOINT ASSEMBLED JOINT Figure 7 20 FasNSeal Connection to Vent Collar 7T Installation of Horizontal Exhaust Terminal a When stainless steel venting is used use U S Boiler stainless exhaust terminal P N 8110701 The outer edge of this terminal must be between 6 and 12 inches from the surface of the wall The joint between the terminal and the last piece of pipe must be outside of the building b Male end of terminal will fit into the female end of any of the approved stainless vent systems c Apply a heavy bead of silicone to the male end of the terminal before inserting it into the last piece of pipe Orient the terminal so that the seam in the terminal is at 12 00 d Smooth the silicone over the seam between the terminal and the last piece of pipe applying additional silicone if necessary to ensure a tight seal e Allow the silicone to cure per the silicone manufacturer s instructions before operating the boiler 29 8 Installation of Vertical Exhaust Terminal Use the terminal supplied by the vent system manufacturer shown in Table 7 5 Attach to the vent system following the assembly instructions in this manual for the stainless vent system being used 9 30 Assembly of the Air Intake System and Air Intake Terminals a Assemble the air intake system using either galvanized or PVC pipe b If PVC piping is used use PVC cement to assemble the PV
39. Ground connection 2 Maximum circulator continuous current draw is 2A When Piping Method 1 is used it may be desirable to use the boiler to directly control the primary circulator in addition to the secondary circulator If this is done control both heating circulators using a relay with a 120VAC coil such as a Honeywell R4222 as shown in Figure 10 3 Select a relay with a contact rating in excess of the combined draw of the two circulators 3 Low Voltage Connections Fig 10 1 These connections are screw terminals located on the terminal strip next to the junction box on the left Terminals 1 and 2 Heating thermostat connections Terminals 3 and 4 External Limit Control connections Terminals 5 and 6 Outdoor Reset Sensor connections Terminals 7 and 8 Domestic Indirect Water Heater thermostat connections Terminal 9 Flame Signal Reading Heat anticipator setting for the thermostat connection is 0 1 A when thermostat is connected directly to terminals 1 and 2 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 THAT COULD BE INADVERTENTLY CONNECTED TO THE LOW VOLTAGE CONNECTIONS IS A TRANSFORMER IN OLD THERMOSTAT WIRING 4 Ifthe outdoor sensor is connected to terminals 5
40. IN IN ACCORDANCE WITH THE ABOVE INSTRUCTIONS COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN PERSONAL INJURY OR DEATH CAUTION BOILER CONDENSATE IS CORROSIVE ROUTE CONDENSATE DRAIN LINE SUCH THAT ANY CONDENSATE LEAKAGE WILL NOT CAUSE PROPERTY DAMAGE SOME JURISDICTIONS MAY REQUIRE THAT CONDENSATE BE NEUTRALIZED PRIOR TO DISPOSAL Condensate Collector Drain o re Vel JARA Vented Dust Cap i Tubing Clamp Not Supplied Rubber M Gasket Condensate x Trap 17 Condensate Tubing Condensate Drain Pipe Not Supplied Figure 7 21 Condensate Piping Arrangement 31 32 VII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fire at the nameplate input at an inlet pressure between the minimum and maximum values shown on the rating plate For more information on gas line sizing consult the utility or the National Fuel Gas Code Figure 8 1 shows typical gas piping connection to the FCM boiler A sediment trap must be installed 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 pre
41. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR FREEDOM CONDENSING HIGH EFFICIENCY DIRECT VENT GAS FIRED HOT WATER BOILER 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 01R1 2 07 VII VIII XI XII XIII XIV XV Table of Contents Product Desenpflion en 2 Specifications rien nes 2 Before E 3 Locating The Bole u een Dil 3 MOUNTING TING BOUNCE c c oce is u 7 Ait FOME NS 10 A A er 12 Vent System aeo i 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 E ee rue 32 O ee ae 33 A General System Piping Precautions 33 System Design susanne 33 C Standard Piping Installation Requirements 40 D Piping For Special 41 MVIEITIQ 43 Stait up and
42. ME TO CHECK FOR GAS LEAKS MAKE SURE THAT THE AREA AROUND THE BOILER IS CLEAR AND FREE FROM COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS 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 until water runs out the condensate drain Reinstall the dust cap 47 48 WATER QUALITY AND BOILER WATER ADDITIVES IMPORTANT NOTE This boiler is equipped with an aluminum heat exchanger that can be seriously damaged by failure to follow the following guidelines Flush the system before connecting the boiler In a replacement installation flushing the system will remove sediment solder flux and traces of old boiler additives Even if the system is new do not omit this step new systems will contain solder flux and may even contain sediment Make sure that the system is tight This is the single most important guideline Tap water contains dissolved oxygen which causes corrosion In a tight system this oxygen comes out of solution and is quickly removed from the system through the automatic air vent The system then remains essentially free of oxygen If the system is not tight however frequent additions o
43. R 5 08 2 a 1 through 4 b EXEMPTIONS The following equipment is exempt from 248 5 08 2 a 1 through 4 1 The equipment listed in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes c MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for the installation of the venting system design or the venting system components and 2 A complete parts list for the venting system design or venting system 4 MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment i
44. Usually at least two circulators will be required to properly install a FCM Series boiler See the previous section for information on sizing the circulators Expansion Tank Required If this boiler is replacing an existing boiler with no other changes in the system the old expansion tank can generally be reused If the expansion tank must be replaced consult the expansion tank manufacturer s literature for proper sizing Fill Valve Required Either a manual or automatic fill valve may be used The ideal location for the fill is at the expansion tank Automatic Air Vent Required At least one automatic air vent is required Manual vents will usually be required in other parts of the system to remove air during initial fill Manual Reset High Limit Required by some codes This control is required by ASME CSD 1 and some other codes Install the high limit in the boiler supply piping just above the boiler with no intervening valves Set the manual reset high limit to 200 F Wire the limit per Figures 10 1 amp 10 2 in the Wiring section Flow Control Valve Required The flow control valve prevents flow through the system unless the circulator is operating Flow control valves are used to prevent gravity circulation or ghost flows in circulator zone systems through zones that are not calling for heat Isolation Valves Recommended Isolation valves are useful when the boiler must be drained as they will eliminate havi
45. Y RATING AFUE VOLUME WEIGHT BTU hr BTU hr BTU hr BTU hr Add suffix N for natural gas and for propane Ratings are the same for both fuels TABLE 2 3 MAXIMUM VENT LENGTHS Using 60 100mm Concentric Vent System Supplied with the Boiler Using Optional 60 100mm Concentric Vent Components See Vent Section for additional venting options and requirements 1 2 3 4 5 6 1 2 3 4 5 III Before Installing 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 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 Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be exceede
46. adjustments Improper gas valve or mixture adjustments could result in property damage personal injury or loss of life 12 Test any external limits or other controls in accordance with the manufacturer s instructions 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 type of system to which this boiler is connected See the Operation section of this manual for information on how to do this 15 Adjust the heating and indirect water heater thermostats to their final set points 52 1 2 XII Operation The FCM boiler uses a microprocessor based control known as a MCBA to manage all boiler functions including flame supervision and modulation Two set point or target boiler supply temperatures are stored in the MCBA s memory one for space heating and one for domestic water production If an outdoor temperature sensor is connected to the boiler the space heating supply set point will automatically adjust downwards as the outdoor temperature increases For more information on this feature see the discussion on boiler water reset below The MCBA modulates the boiler input by v
47. alyzer probe in the sensor opening For the boiler to operate this sensor will need to be remain connected to the wiring If the flue gas sensor is removed be sure to replace it after combustion testing is complete Check CO or O and CO at both high and low fire The boiler may be temporarily locked into high or low fire for 15 minutes as follows a To lock the boiler in high fire simultaneously 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 been driven to low fire After this happens allow the boiler to operate for approximately 5 minutes before taking combustion readings c Normal modulation of the boiler should return 15 minutes after the boiler is locked in high or low fire At both high and low fire CO readings should be less than 75 PPM Typical CO readings are shown in Table 11 3 TABLE 11 3 TYPICAL CO O COMBUSTION READINGS RANGE CO 0 51 WARNING Each FCM series boiler is tested at the factory and adjustments to the air fuel mixture are normally not necessary Consult a U S Boiler representative before attempting to make any such
48. 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 1 Apply silicone as in step d Fig 7 17b j Align the longitudinal seams of the pipe and insert the male end of the second pipe into the female end of the first pipe k Insert Star 34 joiner band into the inlet of the beaded channel Feed the joiner band in so that it makes its way around the channel and overlaps by approximately gt Fig 7 17b 1 Cut the excess joiner band so that it lays flat in the beaded channel Fig 7 17b m Fill the inlet of the beaded channel with silicone Smooth the silicone over the channel inlet as well as the silicone between the female end and the stop bead of the male end Fig 7 17b n Repeat Steps h m for the remaining Star 34 components p Allow the silicone to cure per the silicone manufacturer s instructions before operating the boiler BEAD K CC STAR 34 MALE END 1 4 SILICONE BEADS REPLACE AND REMOVE CLAMP BEFORE TIGHTEN CLAMP P INSERTING PIPE i SMOOTH SILICONE OVER THIS JOINT VENT COLLAR UNASSEMBLED JOINT ASSEMBLED JOINT Figure 7 17a Star 34 Connection to Vent Collar STOP BEAD STAR 34 MALE END 1 47 SILICONE BEADS SMOOTH SILICONE CORRUGATED JOINER BAND OVER THIS JOINT TRIM JOINER BAND STAR 34 FEMALE END COVER WITH SILICONE UNASSEMBLED JOINT ASSEMBLED JOINT Figure 7 17b Star 34
49. any disagreement arising in connection with a claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Burnham Hydronics m
50. arying the fan speed As the fan speed increases so does the amount of gas drawn into the blower As a result a fairly constant air fuel ratio is maintained across all inputs The MCBA determines the input needed by looking at both current and recent differences between the supply temperature and the set point temperature As the supply temperature approaches the set point temperature the fan will slow down and the input drop Depending on the model boiler the minimum input is between 14 and 1 5 of maximum input The MCBA also monitors boiler return and flue temperatures In addition all other safety 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 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 Mode Used to change control settings Information Mode Displays boiler operating temperatures Under normal conditions the boiler is in standby mode and the display looks like that shown in Figure 12 1 The three digits to the right of the decimal point are the boiler s supply temperature The digit to the left of the decimal point is the boiler s status code A list of status codes and their meanings is shown in Table 12 3 Figure 12 2 i
51. ction Air Separator amp Air Vent Automatic Fill Valve Cold Water Line Swing Check Valve Unions Isolation Valves IWH Circulator Swing Check Valve Indirect Domestic Water Heater IWH Relief Valve 2 Figure 9 46 Piping Method 1 Indirect Water Heater Loop Piping Shaded FROM SYSTEM Ep HEATING LOOP CIRCULATOR PRIMARY CIRCULATOR BOILER LOOP CIRCULATOR CHECK VALVE EXPANSION TANK BOILER 1 BOILER LOOP CIRCULATOR CHECK VALVE Z Figure 9 4c Modular Boiler Piping BOILER 2 BALANCING VALVE 2 REQUIRED IF BOILERS ARE DIFFERENT SIZES TO SYSTEM MODULAR BOILER PIPING PREFERRED 37 38 TABLE 9 5 PIPE AND CIRCULATOR SIZING FOR BOILER LOOP d BOILER PIPE BOILER LOOP MODEL SIZE CIRCULATOR MAX EQUIVALENT LENGTH in NPT mama 61 28 1 1 1 1 1 1 120 1 Taco 0013 Note 1 mo NOTE 1 Use isolation relay between Taco 0013 and FCM see Figure 10 3 TABLE 9 6 PIPE AND CIRCULATOR SIZING FOR INDIRECT WATER HEATER LOOP a c d e f MAX LW H 1 W H LOOP MAX 4 PRESSURE ALLIANCE CIRCULATOR EQUIVALENT DROP INDIRECT WATER OBER LENGTH 070 090 090 120 120 120 HEATERS AL27SL AL35SL ALTOSL 9 Taco 008 AL119SL AL27SL AL35SL ALSOSL
52. d in the planned installation Also verify that the vent terminal can be located in accordance with Section VII Make sure that the boiler is correctly sized Forheating systems employing convection radiation baseboard or radiators use an industry accepted sizing method such as the 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 Forsystems that incorporate other indirect water heaters refer to the indirect water heater manufacturer s instructions for boiler output requirements Make sure that the boiler received is configured for the correct gas natural or LP Make sure that the boiler is configured for use at the altitude at which it is to be installed NOTICE This product must be installed by a licensed plumber or gas fitter 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 Observe the minimum clearances shown in Figure 4 1 These clearances apply to both combust
53. e configured for continuous pump operation If the heating zone is set for continuous pump operation parameter 3 set to 3 the heating pump will still shut down when there is a call for domestic hot water If either the heating supply set point parameter 4 or the DHW reference set point parameter 1 are set above their factory set values the boiler supply temperature will exceed 180 F and there is a possibility that the safety temperature limit will open If this happens the boiler will shut down and a b26 error will appear on the display The boiler will resume normal operation without manual intervention when the safety limit closes this behavior is common on conventional boilers Information mode is used to view various temperatures and settings but cannot be used to change parameters or otherwise control the boiler The information available is shown in Figure 12 2 and is largely self explanatory The digit to the left of the decimal point is the Step number and the digits to the right are the corresponding temperature In information mode the supply water temperature set point Step 6 is the supply temperature set point for the zone to which the boiler is currently responding either heat or DHW If an outdoor sensor is connected to the boiler and the boiler is responding to a call for heat this value will be the current point on the reset curve When no call for heat or DHW is present Step 6 shows the heating supply se
54. e equivalent lengths of all fittings in the secondary loop Total these equivalent lengths and add them to the total length of planned straight pipe in the secondary loop The 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 Indirect Water Heater Loop Piping If Indirect Water Heater is Used All piping must be the size shown in Table 9 6 column a Ifthe indirect water heater connections are smaller than the pipe size called for in column a reduce the pipe size at the indirect water heater connections To size the circulator a Count all fittings in the planned Indirect Water Heater Loop the indirect water heater loop consists of the shaded piping in Figure 9 4b In doing so you will be counting some piping and fittings which are common to the heating system secondary boiler loop piping and which were counted in Step 2a above Do not count the elbows or fittings supplied with the boiler b Using Table 9 7 find the equivalent lengths of all fittings in the indirect water heater loop Total these equivalent lengths and add them to the total length of planned straight pipe in the indirect water heater loop The result is the total equivalent length of the indirect water heater loop c Using Table 9 6 fi
55. e 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 Aclearance 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 soffits or overhangs Maximum depth of overhang is 3 ft Vent terminal must be at least 6 feet from an inside corner Under certain conditions water in the flue 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 flue gas condensate they should be moved or protected If possible install the vent and air intake terminals on a wall away from the preva
56. ed as a guarantee of workmanship of an installer connected with the installation of the U S Boiler Company Inc boiler or as imposing on U S Boiler Company Inc liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation which liability is expressly disclaimed Inc be liable for incidental indirect special or consequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss of time U S Boiler Company Inc liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade water boiler involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 8 Limitation of Warranties These warranties set forth the entire obligation of U S Boiler Company Inc with respect to any defect in a residential grade cast aluminum water boiler and U S Boiler Company Inc shall have no express obligations responsibilities or liabilities of any kind whatsoever other than those set forth herein These warranties are given in lieu of all other express warranties ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD
57. ems 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 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 8 for the maximum vent length In horizontal vent systems the lengths shown in Table 7 1 are in addition to the first elbow on top of the boiler For vertical vent systems the maximum vertical vent lengths shown in Table 7 8 are in addition to two elbows If more elbows are desired the maximum allowable vent length must be reduced by the amount shown in Table 7 7 for each additional elbow used Termination fittings 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 12 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
58. ent calls for burner operation should result in a flame on the first try 9 Inspect the flame visible through the window On high fire the flame should be stable and mostly blue Fig 11 1 No yellow tipping should be present however intermittent flecks of yellow and orange in the flame are normal INNER CONE Well Definec Ker er OUTE ar Transparent X ST ON LOW FIRE Orange Glow 7 2 BURNER SURFACE NOTES 27 IER OUTER CONES MAY NOT Figure 11 1 Burner Flame 10 Check the inlet pressure and adjust if necessary Verify that the inlet pressure is between the upper and lower limits shown on the rating plate with all gas appliances on and off WARNING THE OUTLET PRESSURE FOR THE GAS VALVE HAS BEEN FACTORY SET AND REQUIRES NO FIELD ADJUSTMENT THIS SETTING IS SATISFACTORY FOR BOTH NATURAL GAS AND PROPANE ATTEMPTING TO ADJUST THE OUTLET PRESSURE MAY RESULT IN DAMAGE TO THE GAS VALVE AND CAUSE PROPERTY DAMAGE PERSONAL INJURY OR LOSS OF LIFE 50 OUTLET TAP nl 4 2 REGULATOR THROTTLE MAN DO NOT ADJUST INLETTAP GAS INLET Figure 11 2 Gas Valve Detail 11 Perform a combustion test Boilers equipped with a concentric vent system have a flue gas sample tap located in the boiler vent collar under the screw cap For other vent systems the sample probe may be inserted into the terminal If this is not possible remove the flue temperature sensor and insert the an
59. er is removed from a common chimney the common venting system may be too large for the remaining appliances At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as practical close all building doors and windows and all doors between the space in which all the appliances remaining connected to the common venting system are located and other spaces of the building Turn 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 for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been d
60. etermined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliances to their previous condition of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 WARNING NEVER COMMON VENT A FCM BOILER WITH OTHER APPLIANCES 20 Assembly of U S Boiler 60 100mm Concentric Venting WARNING Failure to follow the instructions could result in flue gas leakage into the combustion air or indoor air resulting in unsafe or unreliable operation Do not lubricate concentric gaskets with anything other than water Do not attempt to cut any piping except as permitted in this section When cutting these sections make sure all cuts are square and allow for proper insertion Do not attempt to try to mix this concentric pipe with other venting systems NEVER COMMON VENT A FCM BOILER WITH OTHER APPLIANCES 1 Concentric vent components supplied with the boiler are packed inside the boiler carton and include the following a 80 125 x 60 100mm reducing elbow P N 101005 01 b
61. f make up water can expose the heat exchanger to oxygen on a continuous basis In addition frequent additions of hard make up water can cause calcium deposits to collect in the heat exchanger causing severe damage To minimize additions of make up water Inspect the system thoroughly for leaks before placing it in service Ifthe system includes underground piping or other piping in which a leak might go undetected consider isolating 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 Radiant Tubing and Oxygen Barriers Even if the system is tight oxygen can be introduced into the system through some types of non metallic tubing used in radiant or snow melt systems Other non metallic tubing is equipped with an oxygen barrier to prevent migration of oxygen into the water If the boiler is to be installed in a system containing non metallic tubing without an oxygen barrier it must be isolated from the boiler with a heat exchanger as shown in Figure 9 10 Antifreeze Do not use antifreeze unless absolutely necessary If antifreeze must be used the only permitted antrifreezes are Fernox Alphi 11 Fernox CHP in virgin propylene glycol available from U
62. 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 12 should flash on the display Push the reset button on the display to restore normal operation If the yellow light does not come on determine why the low water cutoff is not working properly b Follow the procedure for turning the boiler off found in the FCM Series Lighting and Operating Instructions c Inspect the wiring to verify the conductors are in good condition and attached securely CAUTION LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING Remove the ignition electrode and inspect it for oxides Clean the oxides off the electrode with sandpaper Inspect the ceramic insulator for cracks and replace the ignitor assembly if necessary Remove the fan gas valve assembly from the burner hood Inspect for lint and 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 Remove the burner hood to access the burner and the combustion chamber Remove the burner and vacuum
63. gravity circulation during the cooling cycle 41 Oxygenated From Oxygenated System Do Not Exceed 1 Boiler u 2 Indirect IWH Water Heater If Used 3 Isolation Valve 4 Swing Check Valve 5 Central Heating Secondary Circulato 6 IWH Circulator 7 Central Heating Primary Circulator 8 Plate Heat Exchanger 9 Air Separator 10 Automatic Air Vent 11 Expansion Tank 12 Automatic Fill Valve 13 Cold Water Line 14 Relief Valve 15 Relief Valve Discharge Piping 16 Drain Valve 17 Primary Secondary Connection 19 Probe LWCO Figure 9 10 Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger WATER CHILLER HEATING SHUT OFF BOILER SHUT OFF VALVES VALVES Pri AIR CUSHION 1 lt CIRCULATOR SUPPLY MAIN RETURN MAIN FROM COMBINED HEATING COMBINED HEATING amp COOLING SYSTEM 8 COOLING SYSTEM Figure 9 11 Chiller Piping 42 X Wiring WARNING All wiring and grounding must be done in accordance with the authority having jurisdiction or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 1 Line Voltage 120 VAC Connections Fig 10 1 The line voltage connections are located in the junction box on the right side of the vestibule Black Line voltage hot White Neutral for boiler and circulators Red Heating circulator hot Blue Indirect Water Heater circulator hot Green
64. he control If problem reoccurs replace the MCBA 6 Parts All FCM Series Repair Parts be obtained through your local Burnham Wholesale distributor Should you require assistance in locating a Burnham distributor in your area or have questions regarding the availability of Burnham products or repair parts please contact Burnham Customer Service at 717 481 8400 or Fax 717 481 8408 63 64 K EY 1 2 3 5 7 10 11 12 13 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 31 33 34 35 36 37 41 Not Shown PARTS LIST Quantity Part Number DESCRIPTION 070 mm A 34 BSP x 1 2 Steel Nipple Gauge Sensor Well 00376 0 100363 0 1 Gauge Cap Tube Clamp 1 100377 0 1 High Limit 00517 0 Burner Hood Cover Plate Gasket 100381 0 9 2 i 2 i 2 M6 Nut with Captive Washer Return Temperature Sensor 100391 0 1 ID x 1 CSST Adaptor 2 100393 0 em n e m X m I 1 E 2 H m A e o m ES n E 1 x 12 Gray Coated CSST Nut by Nut 100394 0 34 x 1 Black Reducing El 1 100395 0 Quantity Part Number 090 00362 01 00487 01 00364 01 00542 01 00537 01 00536 01 00368 01 00453 01 00542 01 00371 01 00372 01 01164 01 00373 01 00374 01 00375 01 003
65. he 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 b 5 provided with the boiler into the end of the extension as shown in Figure 7 21 Condensate is slightly acidic Do not use metallic pipe or fittings in the condensate drain line Do not route the drain line through areas that could be damaged by leaking condensate Some jurisdictions may require that the condensate be neutralized before being disposed of Dispose of condensate in accordance with local codes Do not route or terminate the condensate drain line in areas subjected to freezing temperatures If the point of condensate disposal is above the trap it will be necessary to use a condensate pump to move the condensate to the drain In such cases select a condensate pump that is approved for use with condensing furnaces If overflow from this pump would result in property damage select a pump with an overflow switch and use this switch to shut down the boiler Alternatively if heat is a necessity use the overflow switch to trigger an alarm Do not attempt to move the trap from the location shown in Figure 7 21 Do not attempt to substitute another trap for the one provided with the boiler The vent shown in Figure 7 21 must be left open for the trap to work properly WARNING FAILURE TO INSTALL THE CONDENSATE TRAP AND CONDENSATE DRA
66. ible and non combustible materials Observe the minimum clearances to combustibles for vent pipe shown in Table 4 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 When the boiler is installed on the floor using the optional pedestal kit the boiler may be installed on a non carpeted combustible surface The relief valve must be installed in the factory specified location 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 fluorocarbons paint removers cleaning solvents and detergents Clearance From Coaxial Vent Pipe To Combustibles 0 Removable Front ES Access Panel Top View p 17 718 Front View CLEARANCES TO COMBUSTIBLE NON COMBUSTIBLE CONSTRUCTION THIS BOILER IS APPROVED FOR CLOSET INSTALLATION WITH THE ran x NES TOP 7 1 2 FRONT 3 4 SIDES 1 4 RECOMMENDED SERVICE CL
67. iler with galvanized PVC or any other vent system not listed in Table 7 6 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 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 flue gas are routed between the boiler and outdoors using separate pipes Vertical Twin Pipe Venting Vent system exits the building through a roof Combustion air and flue 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 8 For clarity these vent options are nu
68. iling wind Reliable operation of this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph e 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 13 TABLE 7 1 SUMMARY OF HORIZONTAL VENTING OPTIONS RESERVED CLASSIFICATION USED IN THIS HORIZONTAL HORIZONTAL RESERVED FOR FOR FUTURE MANUAL CONCENTRIC TWIN PIPE FUTURE USE USE VENT PIPE STRUCTURE PENETRATION VENT TERMINAL En P N 8110701 AIR INTAKE TERMINAL CONCENTRIC 3 90 ELBOW APPROVED U S Boiler STAINLESS 60 100mm TEEL VENT VENT MATERIAL VENT SYSTEM COMPONENTS SHOWN IN SHOWN IN TABLE 7 5 GALVANIZED Note 1 AIR INTAKE MATERIAL OR PVC Note 1 The 80 125mm concentric straight section P N 101162 01 shown in Table 7 4 may be used between the boiler and the first 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 WALL WALL 6 m E o Z e 2 gt lt gt MINIMUM LENGTH 14 APPROVED CONCENTRIC VENT SYSTEM CTABLE 7 4 PITCH VENT PIPE 5 8 PER FOOT TOWARDS BOILER TERMINAL BUILDING EXTERIOR Figure 7 2 Horizontal Concentric Venting Vent Option 1 Figure 7 3 Horizontal Twin Pipe Venting Vent Option 2 15
69. inal through which exhaust could enter the building 5 Ifadditional pieces of pipe are used install them starting at the boiler elbow Support each section of straight pipe at its female end 21 80 125 x 60 100mm Reducing Elbow 80 125mm Concentric Vent Collar Figure 7 10 Installation of Reducing Elbow Concentric Boiler Collar Figure 7 11 Dimension 1 22 6 7 Use locking bands provided join adjacent sections of non cuttable pipe as well fittings male end of the terminal section and other cuttable sections must be held to the female end of the adjoining pipe with at least three 10 x 1 2 sheet metal screws Drill a 1 8 hole through both outer pipes to start this screw Use a drill stop or other means to ensure that the drill bit does penetrate more than 3 8 into the outer pipe Do not use a sheet metal screw longer than 1 2 The only straight pipe that can be cut is the terminal section and the 19 1 2 section P N 100995 01 and the 80 125 straight riser P N 101163 01 To cut this pipe a Cut the 19 1 2 section from the male end After marking the desired length of the outer 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
70. lator and piping to obtain the design flow rate through the heating system as you would on any other heating system All piping between the expansion tank and secondary connection tees must be at least as large as that shown in Table 9 5 column a In order to keep the flow rates in the primary and secondary loops independent of each other provide at least 8 diameters of straight pipe upstream of the first secondary tee and 4 diameters downstream of the second secondary tee Keep the distance between the expansion tank and the first secondary tee as short as practical Secondary Loop Boiler Loop Piping All piping must be the size shown for the boiler in Table 9 5 column a To size the circulator a Select one of the boiler water flow rates shown in Table 9 5 column b for the boiler being installed When selecting the required boiler flow rate keep in mind that if the flow rate in the primary loop exceeds the flow rate through the boiler it will not be possible to obtain a 180F supply temperature in the primary loop This is because the supply water exiting the boiler will be mixed with cooler system return water before entering the radiation b Count all fittings in the planned secondary loop the secondary loop consists of the shaded piping in Figure 9 4a In doing so do not count the secondary connection tees unions or the fittings supplied with the boiler these have already been accounted for c Using Table 9 7 find th
71. ll not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label Setthe thermostat to the lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Remove the front door panel and the upper boiler access panel Open Closed External Boiler Manual Gas Valve 6 Turn the external boiler manual gas valve T Y handle counterclockwise to open gas supply Smell for gas in the boiler enclosure If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn on all electric power to the appliance Set the thermostat to the desired setting The first digit of the control display panel will show a series of numbers that indicate the boiler control sequence The number 3 or 4 means the burner is firing The number 0 means there is no call for heat from the thermostat or the domestic water heater If the appliance will not
72. mbered from 1 to 6 One of the vent option columns in Tables 7 1 or 7 8 must match the planned vent and air intake system exactly In addition observe the following guidelines Approved vent systems Use only one of the approved vent systems shown in Tables 7 4 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 1 1 For longer runs additional straight lengths and elbows are available from U S Boiler 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 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 are made of a special stainless steel alloy AL29 4C for protection against corrosive flue gas condensate They are designed to provide a gas tight seal at all joints and seams so that flue 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 syst
73. ments For Side Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4 00 and 5 00 for installation of side wall vented gas appliances as follows a For all side wall horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed In addition the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling building or structure served by the side wall horizontal vented gas fueled equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a I
74. n standby mode it is also possible to turn on or off either the heating or domestic water zone There is normally no reason to turn off either of these zones and doing so is not recommended CAUTION PUSHING AND HOLDING THE WHILE IN STANDBY MODE WILL PREVENT THE BOILER FROM RESPONDING TO A CALL FOR HEAT PUSHING AND HOLDING THE WHILE IN STANDBY MODE WILL PREVENT THE BOILER FROM RESPONDING TO A CALL FOR DOMESTIC WATER IF THIS HAPPENS cOFF or dOFF WILL APPEAR ON THE DISPLAY TO TURN BACK ON THE HEATING FUNCTION PRESS AND HOLD UNTIL AND THE SET POINT TEMPERATURE APPEARS ON THE DISPLAY TO TURN BACK ON THE DOMESTIC WATER FUNCTION PRESS AND HOLD UNTIL AND THE SET POINT TEMPERATURE APPEARS ON THE DISPLAY AFTER PRESSING ANY KEYS AND BEFORE LEAVING THE INSTALLATION VERIFY THAT THE BOILER FIRES IN RESPONSE TO A CALL FOR HEAT AND DOMESTIC WATER 66 In standby mode if Mode and either or are simultaneously pushed and held for at least 2 seconds the burner can be forced into either high or low fire This feature is used for running combustion 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 b
75. n the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision can not be met at the time of completion of installation the owner shall have 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 metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CM
76. ncentric collar Figure 7 16 Figure 7 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 18 TABLE 7 7 AIR FITTING EQUIVALENT LENGTH VENT FITTING EQUIVALENT LENGTH ft 60 100mm 90 CONCENTRIC ELBOW 60 100mm 45 CONCENTRIC ELBOW 3 90 ELBOW 3 45 ELBOW 6 Permitted Terminals for Vertical Venting Vent Option 5 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 9 7 Vertical Vent Terminal Locations Vent Option 5 Observe the following limitations on the location of all vertical vent terminals see Figure 7 9 The top of vent pipe must be at least 2 feet above any object located within 10 feet 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 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
77. nd MCBA Display Panel Blank Fan running Blown F1 fuse in see Figure 13 2 for location Replace with fuse provided Defective AT250 transformer Display reads U 125 continuously Fan running 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 Boiler is not seeing call for heat Check thermostat or zone wiring for loose display 0 see Figure 11 1 connection miswiring or defective thermostat zone control Loose ribbon cable Boiler fires but display panel is blank Defective display F3 Fuse gt Fuse Figure 14 2 Fuse Location 60 Trouble shooting problems where a soft lockout code is displayed When a soft lockout occurs the boiler will shut down and the display will alternate between the number 9 and the letter b followed by a two digit service code The boiler will automatically restart once the condition that caused the lockout is corrected TABLE 14 3 SOFT LOCKOUT CODES DISPLAYED CODE CONDITION POSSIBLE CAUSES Blockage in intake or vent system Vent and or intake system not constructed in accordance with Part Blocked or leaking pressure switch tubing Heat exchanger or burner blockage Terminals exposed to high winds Blockage in condensate trap above vent Pressure switch circuit open Heating load at time of
78. nd the boiler size being installed and select an indirect water heater loop circulator that shows a maximum equivalent length column f in excess of the total equivalent length calculated in Step b Example Assume that a 120 is to be installed in a heating system along with an Alliance indirect water heater A total of 15 ft of straight pipe will be installed between the boiler and the primary loop A total of 20 ft of straight pipe will be installed between the boiler and the indirect water heater Fittings are arranged as shown in Figure 9 3 A 9 0 GPM flow is required in the boiler loop The MS 40 requires a flow rate of 8 GPM and has a head loss of 3 0 ft Total fittings in Secondary loop boiler loop 6 90 Elbows 2 Runs of Tees 1 Swing Check 2 Isolation Valves Note Unions Secondary Connection Tees and factory supplied fittings are ignored Calculate total equivalent length from Table 9 7 15ft Straight Pipe 6 Elbows x 2 75 2 Runs of Tees x 1 75 1 Swing Check x 7 2 valves x 0 6 43 2 equivalent feet straight pipe From Table 9 5 we see that a Taco 0014 will pump 9 GPM through a FCM120 with 61 equivalent feet of pipe so the Taco 0014 is OK Example contd Total fittings in Indirect Water Heater Loop 5 90 Elbows 2 Turns in Tees 1 Swing Check 2 Isolation Valves 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
79. ng to drain and refill the entire system Drain Valve Required The drain valve is installed on the return tee located in the lower vestibule compartment as shown in Figure 9 2 Low Water Cut off Required The low water cut off supplied with this boiler must not be removed D Piping for Special Situations Systems containing oxygen Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to an aluminum boiler such as the FCM Some examples include Radiant systems that employ tubing without an oxygen barrier Systems with routine additions of fresh water Systems which are open to the atmosphere If the boiler is to be used in such a system it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure 9 10 Consult the heat exchanger manufacturer for proper heat exchanger sizing as well as flow and temperature requirements components on the oxygenated side of the heat exchanger such as the pump and expansion tank must be designed for use in oxygenated water Piping with a Chiller If the boiler is used in conjunction with a chiller pipe the boiler and chiller in parallel as shown in Figure 9 11 Use isolation valves to prevent chilled water from entering the boiler Air Handlers Where the boiler is connected to air handlers through which refrigerated air passes use flow control valves in the boiler piping or other automatic means to prevent
80. nstallation 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 copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts lists for venting instructions and or all venting design instructions shall remain with the appliance or equipment at the completion of the installation 77 78 5 5 79 Limited Warranty FOR RESIDENTIAL GRADE CAST ALUMINUM WATER BOILERS Subject to the terms and conditions set forth below U S Boiler Company Inc Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade cast aluminum water boiler manufactured and shipped on or after January 1 2006 ONE YEAR LIMITED WARRANTY ON RESIDENTIAL CAST ALUMINUM GRADE WATER BOILERS U S Boiler Company Inc warrants to the original owner that its residential grade cast aluminum water boilers comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation If any part of a cast aluminum water boiler is found to be defective in material or workmanship during this one year pe
81. ntial grade cast aluminum water boilers all boiler components manufactured by others but furnished by U S Boiler Company Inc such as burners gas valves and controls will be subject only to the manufacturer s warranty if any 3 Proper Installation The warranties extended by U S Boiler Company Inc are conditioned upon the installation of the residential grade cast aluminum water boiler in strict compliance with U S Boiler Company Inc installation instructions U S Boiler Company Inc specifically disclaims liability of any kind caused by or relating to improper installation 4 Proper Use and Maintenance The warranties extended by U S Boiler Company Inc conditioned upon the use of the residential grade cast aluminum water boiler for its intended purposes and its maintenance in accordance with U S Boiler Company Inc requirements and hydronics industry standards 5 This warranty does not cover the following a Expenses for removal or re installation The homeowner will be responsible for the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith and transportation to and from U S Boiler Company Inc Components that are part of the heating system but were not furnished by U S Boiler Company Inc as part of the residential boiler Improper burner adjustment control settings care or maintenance This warranty cannot be consider
82. otrude 3 8 beyond the outer pipe when reinstalled in the terminal section Figure 7 13 Use a fine tooth hacksaw or a PVC saw to cut the plastic pipe and be careful to cut the pipe square 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 terminal section through the wall from the outside Push the remaining wall grommet over the terminal section on the inside of the wall Push the terminal section into the elbow until the mark made in Step g is no longer visible If necessary the brown gasket in the inner pipe may be lubricated with a few drops of water 1 The terminal section must be attached to the elbow with a single 10 x 1 2 sheet metal screw not supplied at the top of the elbow Drill a 1 8 hole in the location shown in Figure 7 15 Use a short drill bit or a drill stop to ensure that the drill bit does not penetrate the pipe by more than 3 8 Install a 10 x 1 2 screw in this hole Do not use a screw longer than 1 2 long j If not already done make sure that both wall grommets are firmly against the interior and exterior wall surfaces Seal any cracks or other openings near the term
83. p on the vent collar wm Assembly of Saf T Vent EZ Seal Vent Components Clean the male end of the next piece of pipe with an alcohol pad and make sure that it is free of burrs Check the female end of the first piece of pipe to make sure that the gasket is in place and is undamaged Using a slight twisting motion insert the male end of the second fitting into the female end of the first fitting taking care not to dislodge or cut the factory gasket In extremely arid conditions it may be easier to assemble these fittings if the gasket is moistened with water prior to assembly Bend the locking tabs over the locking ring on the adjacent piece of pipe Repeat these steps for the remaining Saf T Vent components LONGITUDINAL SEAM CRIMP CUT END NECESSARY SIUCONE BEADS REPLACE AND TIGHTEN CLAMP REMOVE CLAMP BEFORE CUT AND DISCARD SPIGOT INSERTING PIPE SAF T VENT PIPE VENT COLLAR PREPARATION SMOOTH SILICONE OVER THIS JOINT UNASSEMBLED JOINT ASSEMBLED JOINT Figure 7 19 SAF T Vent EZ Seal Connection to Vent Collar 28 6 Assembly of Protech FasNSeal a FasNSeal General Notes Do not cut 4 FasNSeal pipe Consult FasNSeal instructions for method of cutting other 3 pipe Orient FasNSeal vent components so that the arrows on the piping labels in the direction of flue gas flow Support horizontal piping sections at intervals of 6 feet or less Vertical venting systems must be supported by a
84. r 14 20 x 1 2 Phillips Pan Hd with Ext Washer Boiler Hanging Bracket 14 20 Nylon Insert Lock Nut LH Side Panel RH Side Panel 8 Long Bead Chain Lanyard 6 32 x Ye HWH F Self Tapping Screw 6 32 Wing Nut Rubber Bumper Pinhole Grommet Draw Keeper Bottom Panel Bottom Pan Support Bracket FCM Door Gasket Upper Front Jacket Panel U S Boiler Nameplate 0 32 x gt Machine Screw 0 32 Screw Retainer Nylon Spacer 10 x 0 125 3 16 x 1 2 Slic Pin Lower Front Jacket Panel Heyco 2 Window Latch CM Cam Straight Cam FCM X3 X4 Harness FCM X2 Harness Line Voltage Blower Harness FCM MCBA X1 Harness Violet Jumper Wire 120VAC Pigtail Harness FCM Display Harness FCM Limit Harness FCM Sensor Harness FCM Blower Power Harness Inner FCM Tacho Harness Dungs Gas Valve Harness ignition Cable 12 100423 01 1 038 01 1 2 039 0 1 045 01 4 1 1 4 4 0 2 101042 0 2 10 2 069 0 2 10 2 10 a 1 082 0 10 F 10 E Quantity Part Number 090 1 100450 01 1 100452 01 4 100449 01 4 101031 01 4 1 1 1 100468 01 101032 01 101033 01 101034 01 1 101035 01 12 100423 01 8 2 1 1 1 101040 01 101036 01 101037 01 101038 01 101039 01 1 101041 01 2 2 101043 01 8 1 4 101046 01 101042 01 101044 01 101045 01 1 101047 01
85. rculator is deenergized until the call for DHW is satisfied LL o 9 E o 5 gt 5 o 30 50 0 40 50 Outdoor Air Temp F Figure 12 4 Outdoor Reset Curve 57 2 4 58 XIII Service and Maintenance IMPORTANT WARRANTY DOES NOT COVER BOILER DAMAGE OR MALFUNCTION IF THE FOLLOWING STEPS ARE NOT PERFORMED AT THE INTERVALS SPECIFIED Continuously a Keep the area around the boiler free from combustible materials gasoline and other flammable vapors and liquids b Keep the area around the combustion air inlet terminal free from contaminates c Keep the boiler room ventilation openings open and unobstructed Monthly Inspections a Inspect the vent piping and outside air intake piping to verify they are open unobstructed and free from leakage or deterioration Call the service technician to make repairs if needed b Inspect the condensate drain system to verify it is leak tight open and unobstructed Call the service technician if the condensate drain system requires maintenance c Inspect the water and gas lines to verify they are free from leaks Call the service technician to make repairs if required CAUTION WATER LEAKS CAN CAUSE SEVERE CORROSION DAMAGE TO THE BOILER OR OTHER SYSTEM COMPONENTS IMMEDIATELY REPAIR ANY LEAKS FOUND Annual Inspections and Service In addition to the inspections listed above the
86. recommended because it is often very difficult to accurately calculate the pressure drop through the system In replacement installations 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 new single zone system having a low pressure drop Pressure drop curves for the FCM Series boilers are shown in Figure 9 9 Calculation of the system pressure drop and selection of the circulator must be performed by someone having familiarity with pressure drop calculations such as an HVAC engineer Radiation 1 Boiler 3 Isolation Valve 4 Swing Check Valve 7 Central Heating Circulator 9 Air Separator 10 Automatic Air Vent 11 Expansion Tank 12 Automatic Fill Valve 13 Cold Water Line 14 Relief Valve 15 Relief Valve Discharge Piping 16 Drain Valve 18 Balancing Valve 19 Probe LWCO Figure 9 8 Piping Method 2 Direct Connection of Boiler to Heating System 39 40 Head Loss ft we 19 00 18 00 17 00 16 00 15 00 qHH M EEn 300 FO 12004 3 1 oi D bor io D A A A
87. riod U S Boiler Company Inc will at its option repair or replace the defective part FIFTEEN YEAR LIMITED WARRANTY ON HEAT EXCHANGER The second through 10th year warranty covers only the heat exchanger All other component parts furnished by U S Boiler Company Inc but purchased from other manufacturers shall be limited to their warranties if any U S Boiler Company Inc warrants to the original owner and at its original place of installation that the heat exchanger of its residential grade cast aluminum water boilers will remain free from defects in material and workmanship under normal usage for ten years If a claim is made under this warranty during the first ten years from the date of original installation U S Boiler Company Inc will at its option repair or replace the heat exchanger If a claim is made under this warranty after the expiration of ten years and up to fifteen years from the date of original installation U S Boiler Company Inc will at its option and upon payment of the pro rated service charge set forth below repair or replace the cast aluminum heat exchanger The service charge applicable to a cast aluminum heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows Years in Service 1 10 11 12 18 14 15 16 Boile
88. rs installed outside the 48 contiguous United States the State of Alaska and Canada Damage to the boiler and or property due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instruction manual Any damage of failure of the boiler resulting from hard water or scale buildup in the heat exchanger Any damage caused by improper fuels fuel additives or contaminated combustion air that may cause fireside corrosion and or clogging of the burner or heat exchanger Any damage resulting from combustion air contaminated with particulate which cause clogging of the burner or combustion chamber including but not limited to sheetrock or plasterboard particles dirt and dust particulate See Air Ventilation section of the CHG FCM Installation and Operating Manual Any damage defects or malfunctions resulting from improper operation maintenance misuse abuse accident negligence including but not limited to operation with insufficient water flow improper water level improper water chemistry or damage from freezing See System Piping Start up and Checkout Operation and Service and Maintenance sections of the CHG FCM Installation and Operating Manual Any damage caused by water side clogging due to dirty systems or corrosion products from the system See System Piping section of the CHG FCM Installation and Operating Manual Any damage resulting from natural disaster
89. s a map of the menu structure for the control panel Push the mode key to move from one mode to the next As you change modes the mode you are entering is shown on the display a PARA for Parameter Mode b info for Information Mode Stby for Standby Mode Upon entering standby mode Stby will briefly appear on the display and then the display will show the boiler s status along with the supply temperature Figure 12 1 The control will return to standby mode from any other mode if no key is pressed for 20 minutes 8888 Figure 12 1 Normal Display In Standby Mode Boiler Supply Boiler Status Temperature 53 54 In standby mode it is possible to view both the heating supply set point temperature and the domestic hot water reference set point The domestic hot water reference set point plus 45 F equals the boiler supply set point when it is responding to a call from the indirect water zone It is not the actual domestic hot water set point The FCM is designed for use with a storage type indirect water heater such as the Alliance The domestic water set point is controlled by the thermostat on the indirect water heater The default domestic water reference set point is 135 F and target boiler supply temperature when responding to a call from the indirect water heater is therefore 180 F 135 F 45 F The default heating supply set point parameter 4 is 180 F I
90. selected for the boiler and any needed modifications have been made to the wall use Figure 5 1 to locate holes and Make sure that the horizontal centerline of these holes is level Holes 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 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 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 Hang the boiler on the wall hook as shown in Figure 5 2 If not already done in Step 4 locate and drill holes and D using the ob round slots in the bottom mounting flange Secure the bottom flange 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 and D between the bottom mounting flange 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 floor 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 pedes
91. ssure switch is open If it is the combustion fan will be energized and will ramp up to ignition speed When the air pressure switch closes a 10 second prepurge is activated d After the prepurge the control module energizes gas control valve and the spark for 4 5 seconds If a flame is established and proved the control allows the flame to stabilize for 5 seconds at the combustion fan ignition speed setting If the flame fails to prove the control module will attempt to light the burner 4 more times If a flame is still not established the control will lockout e Once the flame stabilization period has ended the MCBA allows the burner to modulate The actual firing rate is dependent upon the measured current and recent differences between 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 before it turns off g The central heating pump will continue to operate until the room thermostat has been satisfied h A demand for domestic hot water DHW is given priority on FCM series boilers If a call for DHW is received while the boiler is responding to a call for heat the heating ci
92. ssures in excess of psi When pressure testing the gas system at pressures of psi or less isolate the boiler from the gas supply system by closing its individual manual shut off valve f 3 Min Drip Leg l ES Ground Joint Tee Union Front View Cap State Of Massachusetts Requires Manual Shut Off Valve To Be Handle Type Figure 8 1 Gas Connection To Boiler IX System Piping A General System Piping Precautions WARNING INSTALL BOILER SO THAT THE GAS IGNITION SYSTEM COMPONENTS ARE PROTECTED FROM WATER DRIPPING SPRAYING RAIN ETC DURING APPLIANCE OPERATION AND SERVICE CIRCULATOR REPLACEMENT ETC CAUTION THE HEAT EXCHANGER USED IN THE FCM IS MADE FROM A SPECIAL ALUMINUM ALLOY FAILURE TO TAKE THE FOLLOWING PRECAUTIONS COULD RESULT IN SEVERE BOILER DAMAGE BEFORE CONNECTING BOILER MAKE SURE THAT THE SYSTEM IS FREE OF SEDI MENT FLUX AND ANY RESIDUAL BOILER WATER ADDITIVES FLUSH THE SYSTEM IF NECESSARY TO ENSURE THAT THESE CONTAMINATES ARE REMOVED DO NOT CONNECT THIS BOILER TO A SYSTEM THAT IS SUBJECT TO REGULAR ADDI TIONS OF MAKEUP WATER OR ONE WHICH EMPLOYS RADIANT TUBING WITHOUT AN OXYGEN BARRIER DO NOT ADD ANTIFREEZE OR OTHER BOILER WATER TREATMENT CHEMICALS EXCEPT THOSE LISTED IN PART XI OF THIS MANUAL MAINTAIN THE PRESSURE IN THE BOILER A MINIMUM 12 PSI DESIGN SYSTEM TO ENSURE THAT THE FLOW FALLS WITHIN THE LIMITS CALLED FOR IN TABLE 9
93. t least one FasNSeal support An additional vertical support is required after any offset b Remove the hose clamp shipped on the FCM vent collar Bend the three hose clamp tabs on this collar outward slightly Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler Remove dirt grease and moisture from the surfaces to be sealed On the male end of the pipe apply a 14 wide bead of high temperature silicone approximately 1 4 inch from the male end of the pipe Insert the male end of the pipe into the boiler vent collar until it bottoms out Apply an additional bead of silicone over the outside of the joint and the seams on the vent collar and smooth out Fig 7 20 Replace and tighten the clamp on the vent collar other joints in the FasNSeal venting system rely on a gasket in the female end of the pipe for a proper seal 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 per the silicone manufacturer s instructions before operating the boiler FASNSEAL MALE END REMOVE CLAMP BEFORE REPLACE AND INSERTING PIPE 2 TIGHTEN CLAMP L VENT COLLAR C
94. t point In some cases a 22 will appear in Information Mode for a particular reading This means that the reading is not applicable For example 22 will appear for the outdoor temperature Step 4 if no outdoor sensor is connected to the boiler 10 par asey 3341 NNAW 2165 2 1 38N 914 asp eunjn 4 10 2es 4 enjejeduie uunjeJ u eBueuo Jo ajey 5 4 eunjejeduie Kjddns JON JON JON 19 Jajem Alddns Y sdejs s boL 526 an y loN pesn J dwa 10sues esr 10 sel eunje1eduie UNY oul lddns ueeq seu eBueu yeu paseal si FYOLS ueu uselJ IM vao 01 Bues eu seres Bulnes sesesidag Bulnes usemjeg 1 4 081 Bumes 4 061 3 89 jeay 10 189 0 1104 yes lddns snonulluo2 uo dund Z uo L 40 0 7 JesH Speed Ae ds p p l9 uuo2 s 105 5 ou j S umoys ope sejnuiu Jeye euinseJ
95. tal is used the boiler may be installed directly on a non carpeted combustible floor 3 16 In Dia Holes For 5 16 In Lag Screws 1 3 16 IN r Minimum Distance To Side Wall Figure 5 1 Wall Mounting Hole Locations Wall Hook Hanging Bracket 2x4 Wall Stud 3 5 16 Flat 5 16 x 2 Lag Mounting Ed Flange Washer 4x Screw 4x 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 sufficient 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 confined space A confined space is defined 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 confined space Total the input of all appliances in the
96. ted by the vent manufacturer in accordance with their instructions When pipe is cut cut end must be square and carefully de burred prior to assembly 2 General Assembly Notes a Where the use of silicone is called for in the following instructions use GE RTV 106 for the vent collar Air inlet piping sections are sealed with any general purpose silicone sealant such as GE RTV102 PVC air inlet piping sections are connected with PVC cement b Longitudinal welded seams should 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 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 vent collar a Remove the six 10 sheet metal screws which attach the 80 125mm collar to the boiler b Remove the collar from the boiler this may be easier if a twisting motion is applied to the collar while removing it c Lubricate the brown gasket in the female end of the plastic vent stub inside the boiler with a few drops of water d 7 Push the stainless steel vent onto the boiler with slight twisting motion Make sure that the stainless steel vent adaptor is inserted at least 1 into the boiler stub e Secure
97. the collar flange to the top of the boiler with the sheet metal screws removed in Step a Vent Connection Stainless Vent Collar Air Intake Connection 80 125mm Top Of gt m Concentric Boiler FR S Vent Collar Figure 7 16 Installation of Stainless Steel Vent Collar 25 3 Assembly of Flex L Intl Star 34 Vent System 26 a Star 34 General Notes Do not cut Star 34 vent components Support horizontal piping sections at intervals of 48 or less Vertical venting systems must be supported by at least one Star 34 Fire stop An additional vertical support is required after any offset Orient Star 34 components so that the arrows on the piping labels are in the direction of flue gas flow b Start assembly of the vent system at the boiler Remove the hose clamp shipped on the FCM vent collar Bend the three hose clamp tabs on this collar outward slightly c Clean the exterior of the male end of the first piece of pipe and the inside of the vent collar on the boiler Use a cleaner such as Methyl Ethyl Keytone MEK or naptha On the male end of the pipe apply a wide bead of silicone approximately 4 from the end of the pipe and another 14 bead against the joint side of the stop bead Fig 7 172 e Insert the male end of the pipe into the boiler vent collar until it bottoms out d f Apply an additional bead of silicone over the outside of the joint and smooth out g Replace

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