Burnham 101008-01R1-2/07 manual III Before Installing, IV Locating the Boiler

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IIIBefore Installing

1)Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance with this manual and the authority having jurisdiction.

In the absence of an authority having jurisdiction, installation must be in accordance with this manual and the National Fuel Gas Code, ANSI Z223.1.

Where required by the authority having jurisdiction, this installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers (ANSI/ASME CSD-1).

2)FCM boilers utilize aluminum heat exchangers constructed, tested, and stamped in accordance with ASME Boiler and Pressure Vessel Code Case 2382-2. Some jurisdictions which require ASME boiler construction do not recognize this Code Case and may not approve the installation of an aluminum boiler. Consult the authority having jurisdiction before installing this boiler.

3)Read Section VII to verify that the maximum combustion air and exhaust pipe lengths will not be exceeded in the planned installation. Also verify that the vent terminal can be located in accordance with Section VII.

4)Make sure that the boiler is correctly sized:

For heating systems employing convection radiation (baseboard or radiators), use an industry accepted sizing method such as the I=B=R Heat Loss Calculation Guide (Pub. #H21 or #H22) published by the Hydronics Institute in Berkely Heights, NJ.

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

For systems including a Alliance™ indirect water heater, size the boiler to have either the DOE Heating Capacity required for the Alliance™ or the net rating required for the heating system, whichever results in the larger boiler.

For systems that incorporate other indirect water heaters, refer to the indirect water heater manufacturer’s instructions for boiler output requirements.

5)Make sure that the boiler received is configured for the correct gas (natural or LP).

6)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

1)Observe the minimum clearances shown in Figure 4.1. These clearances apply to both combustible and non- combustible materials. Observe the minimum clearances to combustibles for vent pipe shown in Table 4.2.

2)Note the recommended service clearances in Figure 4.1. These service clearances are recommended, but may reduced to the combustible clearances provided:

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

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

3)When the boiler is installed on the floor using the optional pedestal kit, the boiler may be installed on a non-carpeted combustible surface.

4)The relief valve must be installed in the factory specified location.

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

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Contents Freedom Table of Contents Specifications Product DescriptionII Specifications Maximum Vent LengthsIII Before Installing IV Locating the BoilerClearances To Combustible Or Non-combustible Material Clearances from Vent Piping to Combustible Construction Wall Mounting Mounting The BoilerFloor Mounting Wall Mounting Hole Locations Boiler Mounting/Hardware VI Air for Ventilation Page VII Venting Vent System DesignPage Summary of Horizontal Venting Options Or PVCHorizontal Concentric Venting Vent Option U.S. Boiler Concentric Vent Components Vent Option Size Vent6c Positioning Vent Terminal Under Overhangs VENT/ AIR Intake Fitting Equivalent Length Summary of Vertical Venting Options RoofRemoving an Existing Boiler From a Common Chimney Never Common Vent a FCM Boiler with Other AppliancesAssembly of U.S. Boiler 60/100mm Concentric Venting 11 Dimension L 12 Cutting Outer Pipe 14 Preparing Terminal Section for Installation in the Wall Assembly of Stainless Steel Venting 16 Installation of Stainless Steel Vent Collar17a Star-34 Connection to Vent Collar 18 Z-Vent III Connection to Vent Collar 19 SAF-T Vent EZ Seal Connection to Vent Collar 20 FasNSeal Connection to Vent Collar Condensate Trap and Drain Line 21 Condensate Piping Arrangement Viii Gas Piping Gas Connection To BoilerGeneral System Piping Precautions IX System PipingSystem Design Flow Requirements Through BoilerMethod 1 Primary/Secondary Piping Piping Method #1 Heat Only Piping Method #1 Heat + Indirect Water Heater 4b Piping Method #1 Indirect Water Heater Loop Piping Shaded Pipe and Circulator Sizing for Boiler Loop Pipe and Circulator Sizing for Indirect Water Heater LoopFitting Equivalent Lengths Standard Piping Installation Requirements Boiler Head LossPiping for Special Situations 11 Chiller Piping Wiring Wiring Connections Diagram Ladder Diagram Page XI Start-up and Checkout Never Attempt to Fill a HOT Empty BoilerWater Quality and Boiler Water Additives FCM Series Lighting and Operating Instructions SWT Gas Valve Detail Typical CO2/O2 Combustion Readings RangePage Normal Display In Standby Mode XII OperationPage Basic Menu Tree Boiler Status First Digit Boiler StatusOutdoor Reset Curve XIII. Service and Maintenance Page XIV. Troubleshooting No Error Code DisplayedSoft Lockout Codes Displayed Code Condition Possible CausesHard Lockout Codes Displayed XV Parts Page Parts List KEY DescriptionPage Parts List Page Page Page DISP4D 150 151 152 153 154 155 156 157 158 159 160 161 162 Page Page Page Page Page Limited Warranty