MPI FCX Handbuch

1www.monitorproducts.com

Fully Condensing Oil Fired Application Efficiency, Up to 95% efficient

MONITOR PRODUCTS, INC.

P.O. Box 3408 • Princeton, NJ 08543

www.monitorproducts.com

MONITOR FCX

INSTALLATION AND SERVICE MANUAL

As part of its policy of continuous product improvement,

Monitor Products, Inc. reserves the right to make changes without notice

“The availability of these manuals and instructions is not to be construed or interpreted as MPI’s approval, consent, or

authorization for any third party to install, repair, or advise on any actions taken on or with the MPI products described therein.”

FCX INSTALLATION AND SERVICE MANUAL

TABLE OF CONTENTS

I. INTRODUCTION

1 - PRODUCT DESCRIPTION

Model FCX oil fired boiler utilizes a sealed combustion system

that operates at a temperature at which the flue products will

condense. How much the unit condenses depends on return

water temperatures. The lower the temperature the more the unit

condenses and the high the efficiency. The flue products

temperature is so low that the unit is suitable for use with PVC

intake / Polypropylene exhaust flue pipes, which are offered as

standard options for installation. The FCX is approved for installation

with zero clearance to combustible materials by Intertek Testing

Services to the UL Standard for Oil Fired Storage Tank Water

Heaters (UL 732).

The FCX is completely assembled and provides standard parts

as follows:

• An enameled steel cabinet with thick insulation

• A completely unitized, thick shelled boiler with combustion

chamber and a heat exchanger with a system of removable

baffles

• A stainless steel condenser, with condensate drain

• A high efficiency, low emission, gun type oil burner with

combustion air fan, integral oil pump, oil heater and primary

control

• A control panel assembly and all electrical controls for

operation of the boiler, including a water temperature

thermometer in circuit 1

• A manual water-mixing valve that can be motorized if desired

• A safety pressure relief valve

• An expansion tank

• A water circulating pump

• Complete internal water piping terminating in connections for

two independent water heating circuits.

• Complete internal air piping terminating in a connection to a

coaxial flue/combustion air intake system.

Front

View

Side

View

Rear

View

I-INTRODUCTION ..............................................................2

1-PRODUCT DESCRIPTION ........................................... 2

2-DESIGNATION OF COMPONENTS .............................3

3-BOILER OPERATION .................................................. 3

4-PRODUCT STANDARD RATINGS. ..............................4

5-DIAMETER OF PIPE CONNECTIONS. ........................4

II - INSTALLATION............................................................. 4

1 - OPENING THE UNIT ................................................. 4

2 - LOCATION OF THE UNIT ..........................................4

3 - FLUE CONNECTIONS AND ROUTING ...................... 5

4 - ALTERNATIVE FLUE CONNECTIONS .......................8

5 - CONDENSATE DRAIN CONNECTION ..................... 10

6 - WATER CIRCUIT CONNECTIONS ........................... 10

7 - ELECTRICAL CONNECTIONS ................................ 12

8 - FUEL OIL SUPPLY CONNECTIONS ....................... 13

III - START-UP AND OPERATION .................................... 13

1 - PRE-START FINAL SYSTEM CHECK ..................... 13

2 - START-UP AND OPERATION .................................. 13

3 - ADJUSTING THE OIL BURNER ............................... 14

4 - CHECKING THE SAFETY DEVICES ...................... 14

IV - MAINTENANCE ......................................................... 14

1 - CLEANING THE BOILER SHELL ............................ 15

2 - CLEANING THE CONDENSER ............................... 15

3 - BURNER MAINTENANCE ....................................... 15

4 - ADDITIONAL COMPONENT MAINTENANCE ........ 15

5 - EXPANSION TANK PRE-INFLATION PRESSURE .

CHECK ......................................................................... 15

6 - COMBUSTION PRODUCT FLUE ............................. 16

7 - CHANGING ATHERMOSTAT OR THE ..................

THERMOMETER ................................................... 16

V - OPERATING FAULTS................................................. 16

VI - MONITOR PRODUCTS, INC. (“MPI”) LIMITED .....

WARRANTIES ........................................................... 17

VI - FCX PARTS BREAKDOWN. ..................................... 18

VIII - HEAT WISE BURNER .............................................. 21

1 - BURNER WARRANTY ............................................ 21

2 - OPERATING INSTRUCTIONS ................................. 22

3 - SERVICING THE BURNER ..................................... 24

4 - WIRING DIAGRAM .................................................. 26

5 - PARTS BREAKDOWN ............................................ 28

6 - HONEYWELL CONTROLS ...................................... 30

7 - SUNTEC PUMP ...................................................... 44

8 - BS INDIRECT STORAGE TANK .............................. 46

Standard options available from Monitor include:

• Coaxial balanced flue system components for connection to

the boiler to provide venting of the flue products and combustion

air intake.

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Rear View

INTRODUCTION

Front View

2 - DESIGNATION OF COMPONENTS 1) Control Panel

2) Control Panel Cover

3) Safety Pressure Relief

Valve

4) Condenser

5) Manual Mixing Valve

6) Combustion Product

Pressure Test Point

7) Condenser Inspection Port

8) Condensate Drain

View from above

9) Drain Cock

10)Burner Air Inlet Pipe

11)Oil Burner

12)Safety Light and Reset Button

13)Sight Glass

14)Boiler Shell

15)Pockets for Water Overheating

Safety and Thermostat Bulbs

Thermostat

16)Heating Output Sensor

17)Bleed Connection

18)First Circuit Heating Output

19)Second Circuit heating output

20)Combustion Products Flue

21)First Circuit Heating Return

22)Second Circuit Heating Return

23)Well for Combustion Product

Overheating Thermostat Bulb

24)Protection Plate for Electrical

Connections Box

25)Circulating pump

26)Expansion vessel

3 - BOILER OPERATION

Circuit

heating

return 1or 2

2nd circuit

heating

output

Combustion air is drawn into the oil

burner by the burner fan through the

air intake hose connected to the

coaxial flue/combustion air intake/

exhaust separator. Heated air from

combustion of the oil burner cools as it

passes through the boiler heat

exchanger, then the secondary heat exchanger

condenser. Cooled flue products exit the unit through

the center of the flue/combustion air separator tube

assembly. Condensate from the flue products is

drained from the bottom of the condenser into the

condensate drain tube, exiting the unit through the

condensate drain system.

Water is circulated through the boiler heat exchanger

and condenser circuits where it is heated by the

combustion of the oil burner. Two independent water-

heating circuits can be connected to the unit:

• The first circuit passes through a three way

mixing valve incorporated into the boiler. This

valve can either be used manually as supplied

or driven by a motorized controller (option).

• The second circuit can supply another heating

circuit and/or a domestic hot water indirect

storage tank such as BS DHW tanks.

FCX INSTALLATION AND SERVICE MANUAL

INTRODUCTION - INSTALLATION

II. INSTALLATION

4 - PRODUCT STANDARD RATINGS

Ratings for Model FCX are provided in the following table:

Performance Product

Parameter Units Rating

Rated Input BTUH 81,250

Rated Output BTUH 76,000

Combustion Chamber Length Inches 8.98

Combustion Chamber Diameter Inches 11.5

Combustion Chamber Volume Cu. Inches 915

Combustion Prod. Circuit Volume Cu. Inches 3051

Flue Pressure Drop Inches H2O 0.10

Max Heating Service Pressure Psig 43.5

Max Heating circuit water temp Deg. F 176

Water Overheating Safety

Thermostat Setting Deg. F 230

Combustion Prod. Overheating

Safety Thermostat Setting Deg. F 248

Heating Circuit Water Capacity Gallons 4.23

Primary Water Flow Rate

(60/80 deg. C) Gal/hr 254

Water Pressure Drop

(at nominal flow rate) MCE 1.4

Power Absorbed (with burner,

without circulator) KW 0.2

Packaged Weight Lb. 267

Ratings are for the boiler when connected to standard option

coaxial flue system components.

Electrical Power Supply 115 volts, single phase, 60 Hz

Full Load Current 2.0 Amps FLA

Max Fuse/ Circuit Breaker Size 15 Amps

5 - DIAMETER OF PIPE CONNECTIONS

Connection Diameter Units

Combustion Products 3.15 / 4.92 Inch

Water Heating Supply/Return 1 Inch

Domestic Hot Water or

Second Heating Circuit 1 Inch

Condensate Drain 1 -1/2 Inch

Heating Water Drain 1/2 Inch

Air Bleed 3/8 Inch

Safety Pressure Relief Valve 3/4 inch

• Remove the control panel

escutcheon molding (2) by

grasping it on both sides

and pulling it outward

towards you and up. The

escutcheon will come free

of the attachment clips

leaving the control panel

exposed.

1 - OPENING THE UNIT

To open Model FCX to access for installation, and/or service,

• Remove the top cover of the unit (A) by lifting the cover at the

front and rear to free the attachment clips, and then simply

lift the cover straight up and off.

• Remove the front panel attachment screws (P), then pull the

front panel (J) outward towards you at the top to free it from

the attachment clips. Lift the panel up to free it from the

lower attachment pins, and simply lift the panel off.

follow these

steps :

Fig. 4

2 - LOCATION OF THE UNIT

Model FCX is a free standing (floor mounted) appliance suitable

for installation on combustible flooring. It is approved for

installation with zero clearance to combustible walls, ceiling,

doors, etc from the cabinet. Standard option coaxial flue

components are suitable for installation with zero clearance

to combustible materials.

These are operating clearances and it is recommended that

additional clearances be considered:

• Sufficient clearance should be provided in back of the unit to

facilitate installation and maintenance of water, electrical,

flue and condensate drain connections and components.

• Sufficient clearance over the top of the unit should be provided

to allow the top to be removed for service.

• Sufficient clearance from the front of the unit should also be

provided to facilitate adjustments and service.

There is no need for additional clearance to either side of the

unit since there is no access to the unit from either side.

Alternative access measures such as doors, removable wall

panels, etc. may be provided if desired.

Choosing the location should also take into account the total

flue length to the outdoors (See Flue Connection and Routing).

In addition, the choice of location should consider the location

of utilities such as electrical supply and sewer access for

condensate drainage. Location and routing of water lines is, of

course, a significant part of the choice. While Model FCX can be

installed in an enclosure such as a closet, ventilation or other

means must be provided so that the enclosure temperature does

not exceed 113 deg. F (45 deg. C).

5www.monitorproducts.com

OPERATION

3 - FLUE CONNECTIONS AND ROUTING

Connection of the coaxial flue/combustion air piping system

is in the back of the unit to the separator tube assembly. The

combustion products are vented from the boiler and

condenser through the center of the coaxial tube, while the

combustion air is supplied through the outside ring of the

coaxial tube. Since the FCX is a condensing boiler, flue

products exiting the unit are relatively low temperature, typically

from 120 - 212 ° F (49 - 100 ° C), and saturated with humidity.

Consequently, an airtight, corrosion resistant flue system must

be provided.

Various standard option flue piping components and packages

with which to create the flue system are available.

0.98 m Straight Horizontal Flue Kit

Fig. 5

Reference No Length

MPI Part 2201 (N40.28399) 38.6” (980 mm)

Useful length after assy. - 34.6” (0.88 m)

3 m Angled Horizontal Flue Kit

Fig. 6

Reference No MPI Part 2209 (V72.28414)

3 m angled horizontal balanced flue -straight

Fig. 7

Reference only

PP/PVC Concentric Vertical Terminal - For Flat or Sloping

Roof

Fig. 8

Reference No Color Length I.D. O.D.

MPI Part 2206 Black 51.9” 3.15” 4.92”

(1320mm) (80mm) (125mm)

Useful length under roof flashing - 29.5” (0.75 m)

PP/PVC Concentric Horizontal Extension

- joint fitting -

Fig. 9

Reference No Length I.D. O.D.

MPI Part 2202 19.7” 3.15” 4.92”

(N40.28397) (500 mm) (80mm) (125mm)

MPI Part 2203 39.4” 3.15” 4.92”

(N40.28398) (1000 mm) (80mm) (125mm)

Useful length after assy. - 17.7” (0.45 m) or 37.4” (0.95 m)

Roof Flange with Adaptable Coupling

Fig. 10

Reference No Slope Covering type Color

9031 25 - 45 deg Tile/Shingle Red

9032 25 - 45 deg Slate - Shingle Black

Fig. 6 Contains

2 80 mm/1 meter lengths

2 elbows

1 horizontal termination

1 flexible hose clamp and adapter.

NOTE: If the vertical length is more then 1 meter a

45 degree concentric elbow, #2204 or 1/2 meter

extension, #2202, can be used coming out the back

of the unit. This kit must be properly supported.

FCX INSTALLATION AND SERVICE MANUAL

INSTALLATION

PP/PVC Concentric Elbow

- joint fitting -

Fig. 11

Reference No Bend I.D. O.D.

MPI Part 2204 45 deg 3.15” 4.92”

(N40.28395) (80mm) (125mm)

MPI Part 2205 90 deg 3.15” 4.92”

(N40.28396) (80mm) (125mm)

Fastening collar (option)

Fig. 12

Reference No Number Ø mm

MPI Part 2208 3 125

(B00.29727)

Collars are essential to bear the weight of the vertical

extensions so that the boiler does not bear the weight, as well

as horizontal runs preventing sagging and pooling of

condensate.

Polypropylene Roof Plate

Fig. 13

Reference No Color

MPI Part 2207 Black

(A90.12172)

45° bend 90° bend

TYPICAL INSTALLATION EXAMPLES:

The flue/combustion air system piping may be either horizontal

or vertical or a combination of both, observing the following:

• The maximum unrestricted horizontal or vertical flue length

shall not be more than 16.4 ft (5 m), if using the HeatWise

burner.

• For each 90-degree elbow used in the flue system, subtract

3.28 ft (1m) from the total allowable length.

• For each 45-degree elbow used in the flue systems,

subtract 1.64 ft (0.5m) from the total allowable length.

• Horizontal runs of the flue system must pitch back 3/4 inch

per yard (2 cm per m) of length towards the boiler to ensure

proper flue products condensate drainage.

• Termination of a horizontal flue system shall not be less

than 2 ft above grade or 1 ft above average snow level as

shown in fig. 15 and 16 or as dictated by local codes.

• Do not place the flue terminal less than 6.56 ft. (2 m) from

a ventilation hole or opening in a building. NOTE: This is an

important concideration if unit is used year round (domestic

hot water production) where windows may be open.

• Termination of a vertical flue must provide at least 12 inches

(30cm) above the roof jack to the combustion air intake

collar.

• If there are two units in the installation with vertical flue

systems, the termination of the systems must be separated

by 24 inches (60cm).

Fig. 14

All flue-piping components must be assembled and supported

to provide an airtight flue/ combustion air system.

Application of liquid soap over the flue pipes to be joined will

aid in assembly of the parts.

Typical installation examples appear in the illustration that

follow.

Straight Balanced Flue Configuration

Fig. 15

Option: Straight Horizontal Flue Kit

2 ft minimum

7www.monitorproducts.com

INSTALLATION

Fig. 17

Options:

Condensate Tee

Concentric extensions

1 concentric vertical terminal

1 sleeve tile roof flange

1 roof plate

Adjustable supports as needed

max L = L1 + 3.28 ft (1m) < 16.4 ft (5m)_

Fig. 18

Options:

Condensate Tee

3 Concentric extensions

2 45 deg concentric elbows

1 concentric vertical terminal

1 sleeve tile roof flange

1 roof plate

Adjustable supports as needed

Fig. 19

Options:

1 45 deg concentric elbow

Condensate Tee

Concentric extensions

1 concentric vertical terminal

1 sleeve tile roof flange

1 roof plate

max L = L1 + 1.64 ft (0.5 m) + 3.28 ft (1m) < 16.4 ft (5m)_

Note: Use fastening collars as needed. Support leg can consist of a fastening collar attached to a support such as a 2X6 joist.

Angled Balanced Flue Configuration

Fig. 16

Option: Angled Horizontal Flue Kit

max L = L1 + 1.64 ft (0.5m) + L2 + 1.64 ft (0.5m) + L3 +

3.28 ft (1m) < 16.4 ft (5m)

condensate tee

To provide

clearance

around water

connections a

45 degree

elbow can be

used.

To provide clearance

around water

connections a 1/2

meter concentric

extension can be

used

1 ft minimum

above max.

snow level

IMPORTANT: Vertical

lengths longer then 6 ft

(2 meters) should use a

concentric condensate

Tee, #2255, instead of the

concentric 90° elbow to

eliminate condensate

before draining back to

the unit. Condensate tee

must drain properly. It

can be tied into conden-

sate drain of the unit.

FCX INSTALLATION AND SERVICE MANUAL

INSTALLATION

4 - ALTERNATIVE FLUE CONNECTIONS

All combustion appliances consume a quantity of air

proportional to their capacity. If unit is installed using inside

make up air, ventilation louvers must be installed in

confined areas according to code. To avoid corrosion, the

combustion air must not contain any harmful agents.

Halogenated hydrocarbons, containing combinations of

chlorine or fluorine that are found in solvents, paints, glues,

propellants, household cleaning products, etc.

The FCX boiler is a condensing boiler, which means that the

combustion products from the appliance are discharged at

low temperature (120° to 212°F) and saturated with humidity.

Consequently, an airtight, corrosion-resistant flue system

must be provided. It is possible to use an existing flue as

long as it is lined. The lining must be inserted so that it does

not retain any condensate and so that any condensates are

transferred to a drain located at the foot of the flue or directly

back to the boiler condensate trap. The material for the lining

must be chosen specifically for use with a condensing boiler.

Suitable materials certified for use in such combustion

product systems are 904 L stainless steel, PPS

polypropylene, and PVDF. Specialized companies market

these systems and indicate the tubing assembly procedures

to be applied.

Some flue components available from Monitor Products are

as follows:

Flue Connection Adapter -

Adapter is a 4.33 to 3.15 inch (110 to 80 mm) off center reducer.

Fig. 22

Reference No 9103

Rigid Polypropylene Tubes

Fig. 23

Reference No Length inch (m) Ø inch (mm)

2256 39.37 (1) 3.15 (80)

9049 39.37 (1) 4.33 (110)

9102 78.7 (2) 4.33 (110)

Polypropylene Elbows

Fig. 24

Reference No Type Elbow Ø inch (mm)

2259 90° 3.15 (80)

9048 90° 4.33 (110)

Leaf Guard

Fig. 25

Reference No

2210 4.33” (110)

Should be used on the end of 110 mm piping run

Fig. 27

Roof evacuation above the ridge

(Tubing of an existing conduit

negative pressure conduit)

Flue components:

Flue connection kit with off-center reducer (item 1)

4.33 in (110mm) polypropylene tube, 1m long (item 3),

4.33 in (110mm) polypropylene tube, 3m long (item 4),

4.33 in (110mm) 90° polypropylene elbow, (item 5)

L1 < 32.8 ft (10m)

Note:

• With this arrangement, the burner air inlet hose (10) is

disconnected from the burner. The burner draws air directly

into the unit from the premises in which the boiler is installed.

Combustion air must be supplied to the premises with a

vent (11) or alternative means. Condensate drains down the

inside of the flue into the heat exchanger and out the

condensate drain tube.

• If you must deflect the flue system, use 45° degree elbows.

Use 45 degree elbows instead of 90° to lessen flue restrictions.

Use Condensate Tee

9www.monitorproducts.com

INSTALLATION

PPtl/PVC Condensate Tee-Joint

- joint fitting -

Fig. 28

Reference No Length I.D. O.D.

2255 10” 3.15” 4.92”

Length does not include drain spicket

Useful length after assy. 2”

PPtl/PVC Parallel Concentric Adapter (Male/Top)

- joint fitting -

Fig. 29

Reference No Length I.D. O.D.

2253 3.5” 3.15” 4.92”

PPtl/PVC Parallel Concentric Adapter (Female/Bottom)

- joint fitting -

Fig. 30

Reference No Length I.D. O.D.

2254 7” 3.15” 4.92”

45 degree Polypropylene Elbows

Fig. 31

Reference No Type Elbow Diameter

2258 45 degree 3.15”/80mm

2260 45 degree 4.33”/110mm

Typical Installation examples

Fig. 32

Options:

1 90 deg concentric

condensate T #2255

Concentric extensions #2202

1 concentric vertical terminal #2204

1 sleeve tile roof flange

#9031& #9032

1 roof plate #2207

1 adjustable support #2208

1 parallel concentric adapter

# 2253 (male top)

1 parallel concentric

adapter # 2254

(female bottom)

Note: This is using the

Beckett NX Burner

Max L1= 32LF

Each 90* = 3.28lf

Each 45* = 1.64lf

Longer Venting Options:

Longer exhaust lengths can be achieved by using a Beckett

NX burner specifically modified and set up for use with the

FCX. When using the Beckett NX burner the maximum

unrestricted horizontal or vertical flue length shall be no more

then 36 feet if using an 80mm parallel piping system with

PPTL/PVC parallel concentric adapters on each end, or no

more then 30 feet if using concentric PPTL/PVC end to end.

The subtraction of 3.28 feet for 90 degree elbows and 1.6 feet

for 45 degree elbows still applies and must be taken into

account when figuring what the overall length is. It is

recommended that the Heatwise burner be used on overall

lengths of less then 16.4 feet and the Beckett be used on

lengths of 15 to a maximum of 36 feet.

The Beckett NX burner adapted for use on the FCX must have

the following specifications:

The oil line heater is standard with the burner.

The oil pressure is set to (150-155) PSI.

The oil nozzle used is a Danfoss .5-60 degree-AH.

NOTE: Do not use any larger size or supply nozzle with higher

pressure

Combustion readings should be CO 11 - 12.5, smoke 0 - .5

FCX INSTALLATION AND SERVICE MANUAL

6 - WATER CIRCUIT CONNECTIONS

Water circuit connections are made in the back of the unit utilizing

the four 1" male pipe thread couplings provided or using other

adapters provided. The FCX can be connected to various comfort

heating water systems as well as to a domestic hot water heating

system if desired, observing that:

•Water circulating pumps provided in the various circuits must

be large enough for each circuit including the pressure drop of

the boiler/condenser in the unit. For optimum sound level and

power consumption, set the circulator to the speed that is

appropriate for the installation flow rate and pressure drop.

• Isolation valves may be used in the various circuits to facilitate

boiler maintenance without having to completely drain each

circuit. NEVER place an isolation valve between a pressure

relief device and a water tank.

• The water pressure gauge (not supplied) has to be fitted outside

the unit.

INSTALLATION

The FCX comes equipped with the following standard equipment:

1) 8L expansion Tank (Approx. 2.11 US Gallon with acceptance

value of approx. 0.9 gallons) Please refer to expansion tank

manufacturers tables to determine tanks that meet your systems

requirements. Some radiant systems may require special tanks

to meet tubing oxygen requirements.

2) Grundfos UPS1542 Circulator. (see Fig. 35 on page 11 for

pump capacities.) Additional pumps or a primary secondary

system may need to be set up to meet individual system

requirements

3) Safety relief valve. Must be piped away from boiler as per code

using rigid pipe that is the same diameter of the relief valve outlet

approved for the temperature of the system. Discharge pipe

must not cause a hazard or a potential cause of damage to

equipmernt.

CAUTION:

If the pressure relief valve is not piped down and it opens, damage

can occur to the burner.

Fig. 34

1.expansion tank

2.circulating pump

3. safety pressure relief valve

Note: Installed expansion tank is good for up to 25 gallons of

system water. An additional expansion tank is required for more

than 25 gallons. Size accordingly.

5 - CONDENSATE DRAIN CONNECTION

Connection of the condensate drain piping system is to the

condensate drain tube in the rear of the unit beneath the

flue/combustion air separator tube assembly. The condensate

drain tube provided in the unit is 1-19/32 inches (40 mm)

outside diameter over which standard 1-1/2 inch trade size

schedule 40 PVC pipe can be connected to begin the rest of

the drain system. A trap must be provided to prevent leakage

of combustion products into the drain. The drain system must

pitch downward towards the sewer.

Note: The condensate will not likely require any specific water

treatment because of condensate dilution by normal wastewater

use. If, however, local regulations require wastewater to have a

neutral pH condensate treatment tank can be installed between

the trap and the sewer. PH level must be neutralized before

entering a septic tank or cesspool.

Fig. 33

NOTE: Make the trap accessible and removable for cleaning and

do not down size the condensate drain tube until after the trap, if

necessary. If using a condensate pump choose a pump that can

hold up to the corrosive effects of the condensate.

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