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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 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 ............................................................................................... 12 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 FCM070, FCM090 and FCM120 are 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. II Specifications Figure 2.1: General Configuration TABLE 2.2: SPECIFICATIONS MODEL* NO. OF SECTIONS MAXIMUM INPUT (BTU/hr) MINIMUM INPUT (BTU/hr) D.O.E. HEATING CAPACITY (BTU/hr) IBR NET RATING (BTU/hr) AFUE (%) WATER VOLUME (Gal.) APPROX. NET WEIGHT (lb) FCM070 mono block 70,000 30,000 63,000 55,000 95.4 0.41 102 FCM090 mono block 90,000 30,000 80,000 70,000 94.5 0.41 102 FCM120 mono block 120,000 40,000 107,000 93,000 95.2 0.62 110 * Add suffix “N” for natural gas and “P” for propane. Ratings are the same for both fuels. Using 60/100mm Concentric Vent System Supplied with the Boiler................................................................25 in. Using Optional 60/100mm Concentric Vent Components: FCM070 ...................................................................................... 32 ft FCM090 ...................................................................................... 32 ft FCM120 ...................................................................................... 18 ft Using Approved 3” AL29-4C Horizontal Stainless Vent System and Optional Stainless Steel Vent Kit..........55 ft See Vent Section for additional venting options and requirements TABLE 2.3: MAXIMUM VENT LENGTHS 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...