Burnham FCM120 User Manual

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Model: FCM120

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

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

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

101008-01-12/06

Table of Contents

I. Product Description ............................................................................ 2

II. Speciﬁ cations ..................................................................................... 2

III. Before Installing .................................................................................. 3

IV. Locating The Boiler ............................................................................. 3

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

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

VII. Venting ............................................................................................... 11

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

VIII. Gas Piping ......................................................................................... 32

IX. System Piping .................................................................................... 33

A. General System Piping Precautions ........................................... 33

B. System Design ........................................................................... 33

C. Standard Piping Installation Requirements ................................ 40

D. Piping For Special Situations ...................................................... 41

X. Wiring ................................................................................................ 43

XI. Start-up and Checkout ....................................................................... 47

XII. Operation ........................................................................................... 53

XIII. Service and Maintenance .................................................................. 58

XIV. Troubleshooting ................................................................................. 60

XV. Parts ................................................................................................ 63

Appendix A

Special Requirements For Side-Wall Vented

Appliances In The Commonwealth of Massachusetts .................. 76

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

I Product Description

The FCM090 and FCM120 are aluminum gas ﬁ red condensing boilers designed for use in forced hot water heating

systems requiring supply water temperatures of 180°F or less. These boilers are designed for installation on a wall,

however they may be ﬂ oor mounted using an optional pedestal kit available from U.S. Boiler Company, Inc. This

boiler may be vented vertically or horizontally with combustion air supplied from outdoors. This boiler is not

designed for use in gravity hot water systems or systems containing signiﬁ cant amounts of dissolved oxygen.

II Speciﬁ cations

TABLE 2.2: SPECIFICATIONS

MODEL*

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

* Add sufﬁ x “N” for natural gas and “P” for propane. Ratings are the same for both fuels.

NO. OF

SECTIONS

MAXIMUM

INPUT

(BTU/hr)

MINIMUM

INPUT

(BTU/hr)

D.O.E.

HEATING

CAPACITY

(BTU/hr)

IBR NET

RATING

(BTU/hr)

AFUE (%)

WATER

VOLUME

(Gal.)

APPROX.

NET

WEIGHT

(lb)

TABLE 2.3: MAXIMUM VENT LENGTHS

sing 60/100mm Concentric Vent System Supplied with the Boiler................................................................25 in

sing Optional 60/100mm Concentric Vent Components ................................................................................18 ft

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

See Vent Section for additional venting options and requirements

III Before Installing

1) Safe, reliable operation of this boiler depends upon installation by a professional heating contractor in strict accordance

with this manual and the authority having jurisdiction.

• In the absence of an authority having jurisdiction, installation must be in accordance with this manual and

the National Fuel Gas Code, ANSI Z223.1.

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

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

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

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

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

installing this boiler.

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

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

4) Make sure that the boiler is correctly sized:

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

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

in Berkely Heights, NJ.

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

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

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

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

instructions for boiler output requirements.

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

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

NOTICE

This product must be installed by a licensed plumber or gas ﬁ tter when installed within the Commonwealth of Massachusetts. See Appendix A for additional important information about installing this product within the Commonwealth of Massachusetts.

IV Locating the Boiler

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

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

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

to the combustible clearances provided:

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

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

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

combustible surface.

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

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

6) The combustion air piping must terminate where outdoor air is available for combustion and away from areas that will

contaminate combustion air. Avoid areas near chemical products containing chlorine, chloride based salts, chloro/

ﬂ uorocarbons, paint removers, cleaning solvents and detergents.

Figure 4.1: Clearances To Combustible Or Non-combustible Material

TABLE 4.2: CLEARANCES FROM VENT PIPING TO COMBUSTIBLE CONSTRUCTION

MINIMUM CLEARANCE

TYPE OF VENT PIPE PIPE DIRECTION ENCLOSURE

60/100mm

CONCENTRIC VENT-

ING

VERTICAL OR

HORIZONTAL

ENCLOSED ON ALL FOUR

SIDES

TO COMBUSTIBLE

MATERIAL

0”

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

FLEX-L STAR-34

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

FLEX-L STAR-34

HEAT FAB SAF-T VENT

PROTECH FASNSEAL

Z-FLEX Z-VENT III

FLEX-L STAR-34

VERTICAL OR

HORIZONTAL

HORIZONTAL OR VERTI-

CAL WITH OFFSETS

VERTICAL WITH NO OFF-

SETS

AT LEAST ONE SIDE OPEN,

COMBUSTIBLE MATERIAL ON

A MAXIMUM OF THREE SIDES

ENCLOSED ON ALL FOUR

SIDES

ENCLOSED ON ALL FOUR

SIDES

1”

2-1/2”

V Mounting The Boiler

req

CAUTIO

his 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 lled with water. Jurisdictions in areas subject to earthquakes may have special requirements

or supporting this boiler. These local requirements take precedence over the

uirements shown below.

A. Wall Mounting

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

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

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

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

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

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

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

good construction practice and applicable local codes.

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

4) Before mounting the boiler, make sure that wall selected does not have any framing or other construction that will

interfere with the vent pipe penetration.

5) Once a suitable location has been selected for the boiler, and any needed modiﬁ cations have been made to the wall, use

Figure 5.1 to locate holes “A” and “B”. Make sure that the horizontal centerline of these holes is level. Holes “C” and

“D” may also be drilled at this time or after the boiler is hung on the wall. If the 5/16 x 2” lag screws are used, drill

3/16” pilot holes.

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

vent pipe is 4-3/8”.

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

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

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

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

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

5.2).

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

mounting ﬂ ange and the wall to adjust.

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

B. Floor Mounting

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

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

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

Figure 5.1 Wall Mounting Hole Locations

Figure 5.2 Boiler Mounting/Hardwar

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 sufﬁ cient air for ventilation must

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

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

Step 1: Determine whether the boiler is to be installed in a conﬁ ned space - A conﬁ ned space is deﬁ ned by the National

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

space. To determine whether the boiler room is a conﬁ ned space:

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

1000 BTU/hr.

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

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

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

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

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

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

room is a conﬁ ned space.

Example:

A FCM120 and a water heater are to be installed in a room measuring 6 ft – 3 in x 7 ft with an 8 ft ceiling. The

water heater has an input of 30000 BTU/hr:

Total input in thousands of BTU/hr = (120000 BTU/hr + 30000 BTU/hr) / 1000 = 150 MBTU/hr

Volume of room = 6.25 ft x 7 ft x 8 ft = 350 ft

350/150 = 2.33. Since 2.33 is less than 50, the boiler room is a conﬁ ned space.

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

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

the lower opening must be within 12” of the ﬂ oor (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 each have a

minimum free area of 100 square inches.

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

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

even if opening requirements for other appliances are less.

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

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

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

input.

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

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

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

adequate air for ventilation without additional openings into boiler room.

Figure 6.1: Boiler Installed In A Conﬁ ned Space, Ventilation Air From Inside

VII Venting

WARNING

FAILURE TO VENT THIS BOILER IN ACCORDANCE WITH THESE INSTRUCTIONS COULD CAUSE FLUE GAS TO ENTER THE BUILDING RESULTING IN SEVERE PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH:

* Do not attempt to vent this boiler with galvanized, PVC, or any other vent system not listed in 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 ﬂ ue 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 ﬂ ue gas are routed

between the boiler and outdoors using separate pipes.

All of these systems are considered “direct vent” because in all of them, air for combustion is drawn directly from the

outdoors into the boiler. A description of all of these venting options are shown in Tables 7.1 and 7.8. For clarity, these

vent options are numbered 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:

1) 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 ﬁ tting 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 ﬂ ue gas condensate. They are designed to provide a gas tight seal at all joints and seams so that ﬂ ue

gas does not enter the building. Each approved vent system has a unique method for installation - do not attempt to

mix components from different vent systems. A list of approved twin pipe vent systems is shown in Table 7.5. Note

that a special vent collar (U.S. Boiler P/N 101004-01) is required if the boiler is to be vented with one of the approved

stainless vent systems.

2) Maximum Vent and Air Intake Lengths - The maximum length of the vent air intake piping depends upon the vent option

selected and the boiler size. See Table 7.1 or 7.8 for the maximum vent length. In horizontal vent systems, the lengths

shown in Table 7.1 are in addition to the ﬁ rst 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 ﬁ ttings are never

counted, although the length of the concentric terminal section, included with the boiler, is counted.

Example:

A 60/100mm concentric vent system is planned for a horizontally vented FCM120 which has the following components:

80/125 x 60/100mm Reducing Elbow (supplied with the boiler)

5 ft Straight Pipe.

90 elbow

1 ½ ft Straight Pipe

45 Elbow

Uncut Terminal Section (supplied with the boiler)

The Vent Option #1 column in Table 7.1 describes a horizontal direct vent system using 60/100mm concentric vent pipe.

From this column, we see that a FCM120 may have a vent length of up to 18 ft. The 90 degree reducing elbow is not

considered. The length of the terminal section (not including the plastic terminal itself) is approximately 22 1/2” (1.9

ft) installed. From Table 7.7, 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 Lengths - Observe the minimum vent lengths shown in tables 7.1 and 7.8.

4) 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 ﬁ tting is a 90 degree elbow with a

rodent screen supplied by the installer. This elbow is made out of the same material as the rest of the air inlet system

(either galvanized or PVC) and is installed as shown in Figure 7.3.

5) 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 pipe terminals, maintain the correct clearance and orientation between the vent and air intake terminals.

The vent and air intake terminals must be at the same height and their center lines must be between 12 and 36 inches

apart. Both terminals must be located on the same wall.

• The bottom of all terminals must be at least 12” above the normal snow line. In no case should they be less than 12”

above grade level.

• The bottom of the vent terminal must be at least 7 feet above a public walkway.

• Do not install the vent terminal directly over windows or doors.

• The bottom of the vent terminal must be at least 3 feet above any forced air inlet located within 10 feet.

• A clearance of at least 4 feet horizontally must be maintained between the vent terminal and gas meters, electric

meters, regulators, and relief equipment. Do not install vent terminal over this equipment.

• Do not locate the vent terminal under decks or similar structures.

• Top of vent terminal must be at least 5 feet below eves, sofﬁ ts, 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 ﬂ ue gas may condense, and possibly freeze, on objects around the vent terminal including on the structure itself. If these objects are subject to damage by ﬂ ue gas condensate, they should be moved

or protected.

• If possible, install the vent and air intake terminals on a wall away from the prevailing wind. Reliable operation of

this boiler cannot be guaranteed if these terminals are subjected to winds in excess of 40 mph.

• Air intake terminal must not terminate in areas that might contain combustion air contaminates, such as near

swimming pools. See Section IV for

more information on possible contaminates.

TABLE 7.1: SUMMARY OF HORIZONTAL VENTING OPTIONS

VENT OPTION # 1 2 3 4

CLASSIFICATION USED IN THIS

MANUAL

ILLUSTRATED IN FIGURE 7.2 7.3

VENT PIPE STRUCTURE

PENETRATION

AIR INTAKE PIPE STRUCTURE

PENETRATION

VENT PIPE SIZE

AIR INTAKE PIPE SIZE 3”

FCM090

VENT

FCM120

HORIZONTAL

CONCENTRIC

WALL WALL

60/100 mm

CONCENTRIC

18ft

HORIZONTAL

TWIN PIPE

3”

55ft

(RESERVED

FOR FUTURE

USE)

(RESERVED FOR

FUTURE USE)

INLET

VENT

INLET

FCM090

FCM120

FCM090

FCM120

FCM090

FCM120

18ft

10in

60/100 mm

CONCENTRIC

U.S. Boiler

60/100mm

VENT

COMPONENTS

SHOWN IN

TABLE 7.4

55ft

2ft

P/N 8110701

APPROVED

STAINLESS

STEEL VENT

SYSTEM

SHOWN IN

TABLE 7.5

GALVANIZED

OR PVC

LENGTH

MAXIMUM

LENGTH

MINIMUM

VENT TERMINAL

AIR INTAKE TERMINAL 3” 90 ELBOW

VENT MATERIAL

AIR INTAKE MATERIAL

Figure 7.2: Horizontal Concentric Venting (Vent Option 1)

Figure 7.3: Horizontal Twin Pipe Venting (Vent Option 2)

TABLE 7.4: U.S. BOILER CONCENTRIC VENT COMPONENTS (VENT OPTION 1)

USED ON

PART NO. DESCRIPTION SIZE

101005-01

101006-01 TERMINAL SECTION 60/100mm 1 INCLUDED WITH STANDARD BOILER

101007-01 WALL GROMMET 60/100mm 1 INCLUDED WITH STANDARD BOILER

100994-01 39” STRAIGHT 60/100mm 1 OPTIONAL - MAY NOT BE CUT

100995-01 19 1/2” STRAIGHT 60/100mm 1 OPTIONAL - CAN BE CUT

100996-01 90 DEGREE ELBOW 60/100mm 1 OPTIONAL

100997-01 45 DEGREE ELBOW 60/100mm 1 OPTIONAL

80/125 x 60/100mm

REDUCING ELBOW

80/125 x

60/100mm

VENT

OPTION #

1 INCLUDED WITH STANDARD BOILER

COMMENTS

TABLE 7.5: PERMISSIBLE STAINLESS STEEL VENT SYSTEMS AND PRINCIPLE VENT COMPONENTS (VENT OPTIONS 2, 5)

MANUFACTURER VENT SYSTEM SIZE COMPONENT PART NUMBER

3 BOILER COLLAR 101004-01

HEAT FAB

PROTECH

SYSTEMS

INC.

Z-FLEX

FLEX-L INTL. STAR-34

SAF-T VENT

EZ SEAL

FASNSEAL

SVE

SERIES III

(“Z-VENT III”)

3 WALL THIMBLE HEAT FAB 7393, 7393GCS, 5391CI

3 HORIZONTAL TERMINAL 8110701

3 VERTICAL TERMINAL HEAT FAB 9392

3 BOILER COLLAR 101004-01

3 WALL THIMBLE FSWT3

3 HORIZONTAL TERMINAL 8110701

3 VERTICAL TERMINAL FSBS3

3 BOILER COLLAR 101004-01

3 WALL THIMBLE 2SVSWTEF03

3 HORIZONTAL TERMINAL 8110701

3 VERTICAL TERMINAL 24SVSTPF03

3 BOILER COLLAR 101004-01

3 WALL THIMBLE SR03WT15

3 HORIZONTAL TERMINAL 8110701

3 VERTICAL TERMINAL SRTP-03

NOTES:

1) See vent system manufacturer ’s literature for other part numbers that are required such as straight

pipe, elbows, ﬁ restops and vent supports.

2) Part No. 101004-01 collar replaces factory-mounted concentric collar (Figure 7.16).

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

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 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 the 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 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

VENT OPTION # 5 6

CLASSIFICATION USED IN THIS

MANUAL

ILLUSTRATED IN FIGURE 7.9

VENT PIPE STRUCTURE

PENETRATION

AIR INTAKE PIPE STRUCTURE

PENETRATION

VENT PIPE SIZE 3”

AIR INTAKE PIPE SIZE 3”

FCM090

FCM120

VENT

INLET

VENT

INLET

FCM090

FCM120

FCM090

FCM120

FCM090

FCM120

LENGTH

MAXIMUM

LENGTH

MINIMUM

VENT TERMINAL

VERTICAL

TWIN PIPE

ROOF

49.5ft

2ft

STRAIGHT TERMINAL

BY VENT SYSTEM MFR.

(TABLE 7.5)

(RESERVED FOR

FUTURE USE)

AIR INTAKE TERMINAL

VENT MATERIAL

AIR INTAKE MATERIAL GALVANIZED OR PVC

3” 180 ELBOW

(FIGURE 7.9)

APPROVED STAINLESS

STEEL VENT SYSTEM

SHOWN IN TABLE 7.5

Figure 7.9: Vertical Twin Pipe Vent System (Vent Option 5)

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 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 deﬁ ciencies which could cause an unsafe condition.

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 ﬁ replace 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 ﬂ ame of a

match or candle, or smoke from a cigarette, cigar, or pipe.

(f) After it has been determined that each appliance remaining connected to the common venting system

properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace 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

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

WARNING

Failure to follow the instructions could result in ﬂ ue 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) 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) 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) If no 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 ﬁ le or emory cloth.

e) Cut the plastic inner pipe so that it will protrude 3/8” beyond the outer pipe when reinstalled in the terminal section

(Figure 7.13). Use a ﬁ ne 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 ﬁ le, razor blade, or ﬁ ne 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.

i) 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 ﬁ rmly against the interior and exterior wall surfaces. Seal

any cracks or other openings near the terminal through which exhaust could enter the building.

5) If additional pieces of pipe are used, install them starting at the boiler elbow. Support each section of straight pipe at its

female end.

Figure 7.10: Installation of Reducing Elbow on Concentric Boiler Collar

Figure 7.11: Dimension “L”

6) Use locking bands provided to join adjacent sections of 39” pipe as well as ﬁ ttings. The terminal section and the male

end of the 19 1/2” section must be held to the adjoining pipe with at least one #10 x 1/2” sheet metal screw. 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”.

7) The only straight pipe that can be cut is the terminal section and the 19-1/2” section (P/N 100995-01). 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 ﬁ le or emory cloth.

c) Cut the plastic inner pipe so that it will protrude 3/8” beyond the outer pipe when reinstalled in the outer pipe. Use a

ﬁ ne 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 ﬁ le, razor blade, or ﬁ ne sandpaper.

d) Reinstall the inner pipe.

8) Install the terminal as outlined in Step (4) above. Dimension “L” described in Step 4 is the distance from the exterior

surface of the wall to the end of the last piece of pipe inside the building.

Figure 7.12: Cutting Outer Pipe

Figure 7.13: Cutting Inner Pipe

Figure 7.14: Preparing Terminal Section for Installation in the Wall

Figure 7.15: Attaching Terminal Section

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