Burnham 101008-01R1-2/07 - Manuals

Page 2 - Table of Contents

2 Table of Contents I. Product Description ............................................................................ 2 II. Specifi cations ..................................................................................... 2 III. Before Installing ..................................................

Page 4 - III Before Installing; with this manual and the authority having jurisdiction.; NOTICE; IV Locating the Boiler; to the combustible clearances provided:

4 III Before Installing 1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction. • In the absence of an authority having jurisdiction, installation must be in accordance with...

Page 5 - Figure 4.1: Clearances To Combustible Or Non-combustible Material

5 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/fl uorocarbons, paint removers, cleaning solvents and detergents....

Page 7 - V Mounting The Boiler; CAUTION; This boiler weighs approximately 110 pounds:; ) Make sure that the surface to which the boiler is mounted is plumb.

7 V Mounting The Boiler CAUTION This boiler weighs approximately 110 pounds: • Two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when fi lle...

Page 8 - Figure 5.1 Wall Mounting Hole Locations

Page 10 - VI Air for Ventilation; WARNING; room is a confi ned space.

10 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 INJ...

Page 12 - A. Vent System Design; There are three basic ways to vent this boiler:; VII Venting; * Do not obtain combustion air from within the building.

12 A. Vent System Design There are three basic ways to vent this boiler: • Horizontal (“Side Wall”) Concentric Venting - Vent system exits the building through an outside wall. Concentric venting consists of a “pipe within a pipe”. Flue gas exits the building through the inner pipe and combustion ai...

Page 14 - TABLE 7.1: SUMMARY OF HORIZONTAL VENTING OPTIONS

14 TABLE 7.1: SUMMARY OF HORIZONTAL VENTING OPTIONS VENT OPTION # 1 2 3 4 CLASSIFICATION USED IN THIS MANUAL HORIZONTAL CONCENTRIC HORIZONTAL TWIN PIPE (RESERVED FOR FUTURE USE) (RESERVED FOR FUTURE USE) ILLUSTRATED IN FIGURE 7.2 7.3 VENT PIPE STRUCTUREPENETRATION WALL WALL AIR INTAKE PIPE STRUCTURE...

Page 16 - fi restops and vent supports.

16 TABLE 7.4: U.S. BOILER CONCENTRIC VENT COMPONENTS (VENT OPTION 1) PART NO. DESCRIPTION SIZE USED ON VENT OPTION # COMMENTS 101005-01 80/125 x 60/100mm REDUCING ELBOW 80/125 x 60/100mm 1 INCLUDED WITH STANDARD BOILER 101006-01 TERMINAL SECTION 60/100mm 1 INCLUDED WITH STANDARD BOILER 101007-01 WAL...

Page 17 - Figure 7.6c: Positioning Vent Terminal Under Overhangs

17 Figure 7.6a: Location of Vent Terminal Relative to Windows, Doors, Grade Figure 7.6b: Location of Vent Terminal Relative to Meters and Forced Air Inlets Figure 7.6c: Positioning Vent Terminal Under Overhangs

Page 18 - TABLE 7.7: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH; ) Permitted Terminals for Vertical Venting (Vent Option 5)

18 TABLE 7.7: VENT/ AIR INTAKE FITTING EQUIVALENT LENGTH VENT FITTING EQUIVALENT LENGTH (ft) 60/100mm 90 CONCENTRIC ELBOW 4.5 60/100mm 45 CONCENTRIC ELBOW 4.0 3” 90 ELBOW 5.5 3” 45 ELBOW 4.0 6) Permitted Terminals for Vertical Venting (Vent Option 5) - A straight termination is installed in the end ...

Page 19 - TABLE 7.8: SUMMARY OF VERTICAL VENTING OPTIONS

19 TABLE 7.8: SUMMARY OF VERTICAL VENTING OPTIONS VENT OPTION # 5 6 CLASSIFICATION USED IN THIS MANUAL VERTICAL TWIN PIPE (RESERVED FOR FUTURE USE) ILLUSTRATED IN FIGURE 7.9 VENT PIPE STRUCTURE ROOF AIR INTAKE PIPE STRUCTURE ROOF VENT PIPE SIZE 3” AIR INTAKE PIPE SIZE 3” MAXIMUM LENGTH VENT FCM070 4...

Page 20 - B. Removing an Existing Boiler From a Common Chimney; This section does not apply to the installation of a FCM boiler.; NEVER COMMON VENT A FCM BOILER WITH OTHER APPLIANCES

20 B. 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 boiler is removed from a common chimn...

Page 23 - Use a drill stop or other means to; pipe by pulling it out from the female end.

23 6) Use locking bands provided to join adjacent sections of non-cuttable pipe as well as fi ttings. The 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...

Page 25 - Assembly; Figure 7.16: Installation of Stainless Steel Vent Collar

25 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 t...

Page 29 - Figure 7.20: FasNSeal Connection to Vent Collar

29 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 are in the direction of fl ue gas fl ow. • Support horizontal pipi...

Page 30 - E. Condensate Trap and Drain Line; line through areas that could be damaged by leaking condensate.

30 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) Assembly of the Air Intake System and Air Intake ...

Page 31 - Figure 7.21: Condensate Piping Arrangement

Page 32 - VIII Gas Piping

32 VIII Gas Piping Gas piping to the boiler must be sized to deliver adequate gas for the boiler to fi re 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 Ga...

Page 33 - IX System Piping; A. General System Piping Precautions; BOILER MODEL

33 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...

Page 38 - TABLE 9.5: PIPE AND CIRCULATOR SIZING FOR BOILER LOOP

38 TABLE 9.6: PIPE AND CIRCULATOR SIZING FOR INDIRECT WATER HEATER LOOP BOILER MODEL (a) (b) (c) (d) (e) (f) PIPE SIZE FLOW MAX. I.W.H. PRESSURE DROP ALLIANCE™ INDIRECT WATER HEATERS CIRCULATOR MODEL I.W.H. LOOP MAX EQUIVALENT LENGTH (in NPT) (GPM) (ft HEAD) (ft) FCM070 1 6.0 1.7 AL27SL (*)AL35SL (*...

Page 39 - TABLE 9.7: FITTING EQUIVALENT LENGTHS

39 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 fl ow rate through the boiler will equal the fl ow rate through the system. The fl ow rate thro...

Page 40 - PIPE RELIEF VALVE DISCHARGE TO A SAFE LOCATION.

40 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 th...

Page 41 - D. Piping for Special Situations

41 2) Circulator (Required) - 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. 3) Expansion Tank (Required) - If this boiler is replacing an existing boiler with no other changes in the syst...

Page 43 - X Wiring

43 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 “ circ...

Page 44 - iring Connections Diagram

Page 47 - XI Start-up and Checkout; Use the following procedure for initial start-up of the boiler:; NEVER ATTEMPT TO FILL A HOT EMPTY BOILER; • NEVER USE A FLAME TO CHECK FOR GAS LEAKS.

47 XI Start-up and Checkout Use the following procedure for initial start-up of the boiler: 1) If not already done, fl ush the system to remove sediment, fl ux, and traces of boiler additives. This should be done with the boiler isolated from the system. 2) Fill the boiler and hydronic system with w...

Page 49 - FCM Series Lighting and Operating Instructions

Page 50 - SWT

50 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 SETTIN...

Page 51 - Model; Natural Gas; COMBUSTION

51 11) Perform a combustion test. Boilers equipped with a concentric vent system have a fl ue 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 fl ue temperature sens...

Page 53 - XII Operation; ) The display panel has three primary modes of operation. These are:; Figure 12.1: Normal Display In Standby Mode

53 XII Operation 1) The FCM boiler uses a microprocessor based control, known as a “MCBA”, to manage all boiler functions including fl ame 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 wate...

Page 55 - FIGURE 12.2 BASIC MENU TREE

Page 56 - ) Two basic types of errors codes are shown on the display:; First Digit; second prepurge is activated.

56 3) 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 sh...

Page 57 - in postpurge for 35 seconds before it turns off.

57 d) After the prepurge, the control module energizes the gas control valve and the spark for 4.5 seconds. If a fl ame is established and proved, the control allows the fl ame to stabilize for 5 seconds at the combustion fan ignition speed setting. If the fl ame fails to prove, the control module w...

Page 58 - XIII. Service and Maintenance; IMPORTANT; condensate drain system requires maintenance.

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 1) Continuously: a. Keep the area around the boiler free from combustible materials, gasoline and other fl ammable vapors and liquids. b...

Page 60 - XIV. Troubleshooting; A. Troubleshooting problems where no error code is displayed:

60 XIV. Troubleshooting 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 • No 120VAC Power at boiler. Check breaker and wiring between breaker panel and boiler Display Panel Blank, Fan ...

Page 61 - TABLE 14.3: SOFT LOCKOUT CODES DISPLAYED; CODE

61 TABLE 14.3: SOFT LOCKOUT CODES DISPLAYED CODE CONDITION POSSIBLE CAUSES b 08 Pressure switch circuit open • Blockage in intake or vent system. • Vent and/or intake system not constructed in accordance with Part VI. • Blocked or leaking pressure switch tubing • Heat exchanger or burner blockage • ...

Page 62 - TABLE 14.4: HARD LOCKOUT CODES DISPLAYED

62 TABLE 14.4: HARD LOCKOUT CODES DISPLAYED CODE CONDITION POSSIBLE CAUSES E 00 A fl ame signal was present when there should be no fl ame. • Defective gas valve - make sure inlet pressure is below maximum on rating plate before replacing valve. E 02 Flame failure after 5 tries to restart • No gas p...

Page 63 - XV Parts

63 XV Parts All FCM Series Repair Parts may 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 Se...

Page 65 - PARTS LIST

65 KEY DESCRIPTION (Quantity) Part Number (Quantity) Part Number (Quantity) Part Number FCM070 FCM090 FCM120 * Taco 007 (1) 8056170 ----- ----- * Taco 0014 ----- (1) 100362-01 (1)100362-01 * Gas Cock (1) 100487-01 (1) 100487-01 (1) 100487-01 * M4 x 30mm Machine Screw (for gas valve harness) (1) 1003...

Page 76 - adjacent fl oor level.

76 Appendix A: Special Requirements 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 horizon...

Page 77 - installation instructions and

77 (d) 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 fl ue gases, but identifi es “special venting systems”, the following requirements s...

Page 80 - Limited Warranty; FOR RESIDENTIAL GRADE CAST ALUMINUM WATER BOILERS

e. Boilers installed outside the 48 contiguous United States, the State of Alaska, and Canada. f. 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. g. Any damage of failure of ...