MPI Technologies FCX User Manual

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T30.30306.02

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Model FCX oil fired boiler utilizes a sealed combus-

tion system that operates at a temperature at which

the flue products will condense. The flue products

temperature is so low that the unit is suitable for use

with PVC / Polypropylene flue pipes, which are offe-

red as standard options for installation. Model 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).

• A control panel assembly and all electrical con-

trols for operation of the boiler, including a wa-

ter temperature thermometer in circuit 1

• A manual water-mixing valve that can be mo-

torized 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-hea-

ting circuits.

Model FCX is completely assembled and provides

standard parts as follows:

• Complete internal air piping terminating in a

connection to a coaxial flue/combustion air in-

take system.

• 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

Standard options include:

• A stainless steel condenser, with condensate

drain

• Coaxial balanced flue system components for

connection to the boiler to provide venting of

the flue products and combustion air intake.

• A high efficiency, low emission, gun type oil

burner with combustion air fan, integral oil

pump, oil heater and primary control

2.20

34.6

2.28

5.98 5.55

2.20

23.7

27.5

Front view

Side view

Rear view

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View from above

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Front view

Rear view

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Circuit heating

return

2^ndcircuit heating

output

1^stcircuit 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 separator

tube assembly. Heated air from combustion of the

oil burner cools as it passes through the boiler heat

exchanger, then the condenser. Cooled flue pro-

ducts exit the unit through the center of the flue/

combustion air separator tube assembly. Conden-

sate from the flue products is drained from the bot-

tom of the condenser into the condensate drain

tube, exiting the unit through the condensate drain

system..

Water is circulated through the boiler heat exchan-

ger and condenser circuits where it is heated by the

combustion of the oil burner. Two independent wa-

ter-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 regulator (option).

• The second circuit can supply another heating

circuit and/or a domestic hot water production

system.

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Ratings for Model FCX are provided in the following

table:

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Rated Output

8QLWV

BTUH

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76,000

81,250

8.98

11.5

915

Rated Input

BTUH

Combustion Chamber Length

Inches

Cu. Inches

Inches H2O

Psig

Combustion Chamber Diameter

Combustion Chamber Volume

Combustion Prod. Circuit Volume

Flue Pressure Drop

3051

0.10

43.5

176

Maximum Heating Service Pressure

Max Heating circuit water temperature

Water Overheating Safety Thermostat Setting

Combustion Prod. Overheating Safety Thermostat Setting

Heating Circuit Water Capacity

Primary Water Flow Rate (60/80 deg. C)

Water Pressure Drop (at nominal flow rate)

Power Absorbed (with burner, without circulator)

Packaged Weight

Deg. F

Gallons

Gal/hr

230

248

4.23

254

MCE

1.4

0.22

267

Lb.

Ratings are for the boiler when connected to stan-

dard option coaxial flue system components.

115 volts, single phase, 60 Hz

3.0 Amps FLA

Electrical Power Supply

Full Load Current

Max Fuse/ Circuit Breaker Size

15 Amps

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Combustion Products

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Inch

inch

3.15 / 4.92

Water Heating Supply/Return

Domestic Hot Water or Second Heating Circuit

Condensate Drain

1 -1/2

Heating Water Drain

Air Bleed

3/8

3/4

Safety pressure relief valve

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To open Model FCX to access for installation, and/

or service, follow these steps :

- 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 con-

trol panel exposed.

- 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.

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Model FCX is a free standing (floor mounted) ap-

pliance suitable for installation on combustible floo-

ring. It is approved for installation with zero

clearance to combustible walls, ceiling, doors, etc

from the cabinet. Standard option coaxial flue com-

ponents are suitable for installation with zero clea-

rance to combustible materials.

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).

These are operating clearances and it is recommen-

ded 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 con-

densate drain connections and components.

• Sufficient clearance over the top of the unit

should be provided to allow the top to be remo-

ved for service.

• Sufficient clearance from the front of the unit

should also be provided to facilitate adjust-

ments 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, remo-

vable 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 Con-

nection and Routing). In addition, the choice of loca-

tion should consider the location of utilities such as

electrical supply and sewer access for condensate

drainage. Location and routing of water lines is, of

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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 ven-

ted from the boiler and condenser through the cen-

ter of the coaxial tube, while the combustion air is

supplied through the outside ring of the coaxial tube.

Since Model FCX is a condensing boiler, flue pro-

ducts exiting the unit are relatively low temperature,

from 140 - 185 deg. F (60 - 85 deg C), and saturated

with humidity. Consequently, an airtight, corrosion

resistant flue system must be provided.

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42.5 inches 3.15 inch 4.92 inch

(1080mm) (80mm) (125mm)

Various standard option flue piping components and

packages with which to create the flue system are

available.

N40.28393 Tile

42.5 inches 3.15 inch 4.92 inch

N40.28394 Black

(1080mm)

(80mm) (125mm)

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Useful length under sleeve tile - 16.9 inches

(0.43 m)

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38.6 inches

(980 mm)

N40.28399

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19.7 inches

(500 mm)

3.15 inch

(80mm)

4.92 inch

(125mm)

N40.28397

39.4 inches

(1000 mm)

3.15 inch

(80mm)

4.92 inch

(125mm)

N40.28398

Useful length after assy. - 17.7 inches (0.45 m) or

37.4 inches (0.95 m)

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A90.12172

Black

N40.12165 25 - 45 deg

N40.12166 35 - 55 deg

Tile

Slate -

Shingle

N40.12167 35 - 55 deg

Black

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N40.28395

N40.28396

45 deg

3.15 inch

(80mm)

4.92 inch

(125mm)

90 deg

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Collars are essential to bear the weight of the verti-

cal extensions so that the boiler does not bear the

weight.

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All flue-piping components must be assembled to

provide an airtight flue/ combustion air system.

The flue/combustion air system piping may be either

horizontal or vertical or a combination of both, ob-

serving the following:

Application of liquid soap over the flue pipes to be

joined will aid in assembly of the parts.

• The maximum unrestricted horizontal or verti-

cal flue length shall not be more than 16.4 ft

(5 m).

Typical installation examples appear in the illustra-

tion that follow.

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• For each 90-degree elbow used in the flue sys-

tem, subtract 3.3 ft (1m) from the total allowa-

ble length.

• For each 45-degree elbow used in the flue sys-

tem, subtract 1.65 ft (0.5m) from the total allo-

wable length.

1 in

• Horizontal runs of the flue system must pitch

down 3/4 inch per yard (2 cm per m) of length

towards the boiler to facilitate proper flue pro-

ducts condensate drainage.

2.8 ft

• Termination of a horizontal flue system shall

not be less than 5.96 ft(1.8m) above ground

unless other provisions are made to minimize

the likelihood of flue/combustion air intake

blockage.

• Do not place the flue terminal less than 3.3 ft.

(1 m) from a ventilation hole or opening in a

building.

• Termination of a vertical flue must provide at

least 12 inches (30cm) above the roof jack to

the combustion air intake collar.

Option: Straight Horizontal Flue Kit

• If there are two units in the installation with ver-

tical flue systems, the termination of the sys-

tems must be separated by 16 inches (40cm).

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Options:

- 1 90 deg concentric elbow

- 3 Concentric extensions

- 2 45 deg concentric elbows

- 1 concentric vertical terminal

- 1 sleeve tile roof flange

- 1 roof plate

Options:

- 1 90 deg concentric elbow

- Concentric extensions

- 1 concentric vertical terminal

- 1 sleeve tile roof flange

- 1 roof plate

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90° elbow

45° elbow

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rear boiler

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rear boiler

Options:

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- 1 90 deg concentric elbow

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- 1 concentric vertical terminal

- 1 sleeve tile roof flange

- 1 roof plate

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- 3 45 deg concentric elbows

- 1 concentric vertical terminal

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- 1 roof plate

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45° elbow

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Options:

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- 1 concentric extension

- 1 straight horizontal flue kit

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Connection of the condensate drain piping system

is to the back of the unit beneath the flue/combus-

tion air separator tube assembly. The condensate

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

mm) O.D. to which the drain trap assembly supplied

with the unit may be connected. The condensate

drain outlet connection on the trap is 1 - 19/32 in-

ches (40mm) O.D. to which standard 1 -1/2 inch tra-

de size schedule 40 PVC pipe can be connected to

create the rest of the drain system. The drain sys-

tem must pitch downward towards the sewer.

Note: The condensate will not likely require any spe-

cific water treatment because of condensate dilution

by normal wastewater use. If, however, local regula-

tions require wastewater to have a neutral pH, a

condensate treatment tank can be installed

between the trap and the sewer.

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Water circuit connections are made in the back of

the unit utilizing the four 1" male pipe thread cou-

plings provided. Model FCX can be connected to va-

rious comfort heating water systems as well as to a

domestic hot water heating system if desired, obser-

ving that:

• Isolation valves may be used in the various cir-

cuits to facilitate boiler maintenance without

having to completely drain each circuit. NE-

VER place an isolation valve between a pres-

sure relief device and a water tank.

• An expansion tank must be provided in the

system to support an expansion of 6 % of the

total water capacity of all the circuits employed.

• Water circulating pumps provided in the va-

rious 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.

• Safety pressure relief valve must be connected

to the drain.

• The water pressure gauge (not supplied) has

to be fitted outside the unit.

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Flexible fuel oil supply and return lines are supplied

with the unit, and connected to the oil burner. Lines

are terminated with 3/8-inch reverse flare fittings for

connection of the supply and return lines from the

fuel oil tank. When connecting the lines, a 10-micron

Gerber oil filter must be installed in the oil supply line

to minimize burner contamination.

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Electrical power and control connections are made

to pigtail leads that exit through a hole in the right

rear of the unit (facing the front of the unit).

down caused by an unrelated electrical circuit fault,

the unit and any related electrical components

should be connected to a separate branch circuit

specifically dedicated for that purpose.

The power connections must be made in a Listed

junction box that is not provided with the unit. All wi-

ring should conform to the National Electrical Code

and any applicable local codes and standards. To

minimize the likelihood of a heating system shut-

The control circuit connections can be in-air splices

made to pigtail leads provided. Control circuit con-

nections are NEC Class 2, intended for connection

to a typical room thermostat.

W : White

B : Blue

Gy : Grey

Br : Brown

Bk : Black

O : Orange

R : Red

Dk. G :Dark green

Lt. G : Light green

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The hole in the right rear of the unit is a large flat

oval. Mount a Listed 2 x 4 inch, "HandiBox" type

junction box over the oval hole in such manner that

part of the hole is left open. When installing the junc-

tion box, center the box vertically over the oval hole

by using the center knockout in the box. Install a ½

inch trade size cable connector or insulating

bushing in the knockout. Secure the box with screws

as required.

Route the factory supplied main power pigtail leads

through the connector from inside the unit and secu-

re the connector clamp on the wires.

Install a second cable or conduit connector in ano-

ther knockout in the box for the power wiring system

as required. Connect the power wires and groun-

ding conductors to the pigtail leads in the box using

Listed wire connectors and install a cover.

Route the factory supplied control circuit pigtail

leads through the open part of the oval hole from in-

side the unit. Connect the room thermostat wires to

the control circuit pigtail leads using a suitable

Class 2 wiring connection method.

The open part of the oval hole can be either above

or below the junction box depending upon the choi-

ce of wire routing. The Class 2 control circuit leads

will exit the open part of the hole.

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Before starting normal operation of the boiler and

heating system, perform the following final installa-

tion procedures:

freeze solution if appropriate. Open any shut-

off valves in the system.

• Fill the condensate drain trap with water.

• Leak-check the flue/combustion air system to

• Leak-check the fuel oil supply system and

minimize the likelihood of leakage.

open any fuel shut-off valves.

• Leak-check the entire water system, repairing

• Re-check the power and control circuit con-

nections THEN replace all cabinet access pa-

nels.

any leaks that may be found.

• Fill the entire water system with water, treated

as desired for the application, including anti-

• Energize the electrical power circuit to the unit.

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After completing the pre-start final system checks,

the system can be started and run through start-up

checks and adjustments as required.

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To start the boiler, first make sure the room ther-

mostat is set at a high enough temperature to be

closed so that any external water circulating pumps

are running. Turn the boiler On-off switch to the

"ON" position, and set the Boiler Temperature Con-

trol thermostat to its maximum temperature setting.

has expired, the burner will start.

Reduce the Boiler Temperature Control thermostat

setting to make sure the boiler stops properly when

controlled by that thermostat. Increase the room

temperature thermostat setting to make sure that

the circulating pump(s) stop properly.

Turn the Summer-winter switch to "WINTER". This

will start the internal circulating pump. After the start

time delay set on the oil burner (for the oil heater)

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While the oil burner is adjusted at the factory, it is re-

commended that the operating characteristics of the

burner be determined at start-up and readjusted if

necessary. Run the unit long enough at the burner

maximum firing rate to make sure the burner has

reached a stable maximum operating temperature.

THEN, check the burner and adjust as follows:

Check to determine that the smoke spot number

does not exceed 0.5 with a Bacharach control. Ad-

just the burner as required to achieve this maximum.

Check to determine that the CO2 rate is from 12 - 13

percent and that there is no CO production. Adjust

the burner as required to achieve this operating cha-

racteristic.

Measure the temperature of the flue gas exiting the

unit to determine that it does not exceed 250 de-

grees F (120 C).

Combustion inspection can be carried out on the

unit through the hole (item N) provided in the inspec-

tion port (item 7). Be sure to replace the washer

(item M) and the test point screw (item 6) properly

after inspection.

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At the time of start-up, check the safety and control

devices as follows :

- Flame monitoring :

• Check to make sure that the burner shuts

down properly upon the deactivation or discon-

nection of the flame monitoring device or inter-

ruption of the flow of fuel,

- Thermostats :

• Check to see that the thermostat bulbs are

correctly positioned in their housings. This is

essential to provide temperature sensing to

facilitate burner shut-down in the event of

overheating,

- Safety Pressure Relief valve :

• Check the safety pressure relief valve in the

heating circuit for proper operation.

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It is recommend that the boiler and flue/combustion

air system be inspected and maintained annually by

a qualified technician.

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To gain access to the inside of the unit, first remove

the control panel cover escutcheon by grasping it on

both sides and pulling directly outward towards you

and up. Remove any front panel screw(s) and remo-

ve the front panel by pulling the top out towards you

and then lifting up to free the bottom from the moun-

ting pins. Remove the top cover by simply pulling it

up. Remove the electrical terminal block protection

plate by removing the screws in the rear and lifting.

Remove the control panel cover screws and remove

the control panel cover.

The water can be bled from the unit by opening the

drain-cock on the base of the boiler shell using the

tool supplied.

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• Remove the screws (B) from the cast-iron boiler

shell cover (C)

• Remove the flue outlet baffle (D)

• Remove the combustion baffles (E)

• Clean the inner walls of the boiler shell

• Reassemble all the parts the way they were re-

moved, positioning the flue outlet (D) with its

centering screw (P) towards the front of the boi-

ler, then positioning the boiler shell cover (C)

arrow marker opposite the centering screw (P)

• Replace the screws (B) in the boiler shell cover.

ꢂ ꢀ &/($1,1*ꢁ7+(ꢁ&21'(16(5

• Remove the wing nut (F) from the condenser

top cover (G) and remove the cover

• Remove the condenser access plug (7)

• Clean the condenser tubes (H) using a bottle

brush or similar tool

• Observe that the combustion products can flow

freely in the condenser tubes

• Replace the condenser access plug (7) and the

top cover (G), making sure that the seal (I) is

properly positioned when replacing the cover

• Make sure that the seal (I) on the cover and the

access plug is in good condition.

NOTE: If after cleaning the condenser, the tempe-

rature of the flue gasses still exceeds 250

deg. F (120C), perform a boiler check.

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Once adjusted properly, regular maintenance of the

oil burner is not generally required. A routine exami-

nation of the burner should include examination of

the burner fan and nozzle for dirt and the spark elec-

trodes for proper clearances. Replace the fuel filter

if necessary. Cleaning and adjustment is always ap-

propriate during periodic inspection.

If burner firing rate adjustment is required, follow

instructions in "Adjusting the Oil Burner".

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Check to see that the safety and regulation devices

(safety relief valve, air bleed valve, control box com-

ponents, etc.) are operating properly. Check also to

see that the condensate drain siphon is clean. If ne-

cessary, remove the bottom of the siphon, clean it,

replace it and then refill the siphon it with water. Also

check to see that neither the installation nor the boi-

ler have any water or fuel leaks (leaks may produce

a risk for safety and shorten the lifespan). If it beco-

mes frequently necessary to add water to maintain

pressure in the installation, even though no leaks

have been discovered, perform an expansion tank

check.

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Reduce the pressure in the heating installation by

opening the drain cock or the safety valve until the

pressure gauge reading is less than 7 - 8 psig (0.5

bar)

pre-inflation pressure of the tank after totally

bleeding any air from the installation.

Check the pressure in the expansion tank and if ne-

cessary bring it back up to pressure. Replace the

tank if the membrane is punctured (water present in

the inflating valve)

To optimize the efficiency of the expansion tank:

• Adjust its pre-inflation pressure in line with the

installation. The pressure must correspond to

the static height of the installation (H), the

height between the highest point of the

installation and the expansion tank, as

expressed in bars where 10 meters in height =

1 bar.

Dilated water

volume

Water inlet

Membrane

Max vessel

volume

Pressure rises as the

air is compressed

Inflating valve

• Adjust the filling pressure of the installation to

a value greater than 3 psig (0.2 bar) above the

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Examine the flue/combustion air system for leaks

and obstructions. Leaks can generally be detected

by the appearance of condensate stains on the out-

side of the pipes. Replace any damaged seals if ne-

cessary. The flue/combustion air pipe can be

cleaned with running water, if necessary, providing

that the water flow is not too great to be drained

through the condensate drain system. Leave the ex-

cess water in the condensate trap when cleaning is

completed.

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Replacement of the thermostats or the thermometer

requires removal of the bulb from its location and the

control from the control box.

remove the thermostat. Replace the thermos-

tat with another, routing the bulb capillary the

same way as the original, replacing the bulb

properly into the pocket as far as possible.

• The bulb for the Boiler Temperature Thermo-

meter is located on the first circuit heating out-

put tube. Remove the bulb from the tube,

remove the thermometer mounting screws in

the control box and remove the thermometer.

Replace the thermometer with another, routing

the bulb capillary the same way as the original,

replacing the bulb on the tube properly and as

securely as possible.

• The bulb for the Combustion Product Overhea-

ting Thermostat is located in a well provided in

the condenser access plug/inspection port.

Remove the combustion test point plug and

washer from the inspection port to free the

thermostat bulb, and remove the bulb from the

well. Remove the thermostat mounting screws

in the control box and remove the thermostat.

Replace the thermostat with another, routing

the bulb capillary the same way as the original

and replacing the bulb properly into the well as

far as possible. Replace the combustion test

point plug and washer in the inspection port,

securing the bulb in place.

• The bulbs for the Boiler Temperature Control

Thermostat and the Water Overheating Safety

Thermostat are both located in pockets on the

side of the boiler shell. To change either, remo-

ve the bulb from the pocket, remove the ther-

mostat mounting screws in the control box and

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During the course of seemingly normal operation,

there may be operating faults experienced in the

system. Some of the more common faults that may

be encountered are:

%851(5ꢁ)$8/7ꢁ6+87ꢀ'2:1 - The burner may

shut down for any of several reasons, at which point

the burner safety device light (red) on the control pa-

nel will be ON and the there will be a green fault in-

dicator light lit on the oil burner. This may be caused

by a loss of fuel oil (tank empty?), a fouled oil spray

nozzle in the burner, or perhaps a fouled or faulty

flame sensor. To attempt a re-start after correcting

any burner problem and the fuel supply is assured,

push the reset button on the burner. The burner

should re-start after the preset time delay period ex-

pires.

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'2:1 - Opening of either the Water Overheating

Safety Thermostat or the Combustion Product

Overheating Thermostat will result in an oil burner

shutdown. In either case, the burner safety device

light (red) on the control panel WILL REMAIN OFF,

and the green fault indicator light on the oil burner

will REMAIN OFF. The only way to tell if either

device has opened is to check electrically or check

the position of the reset button, located under the

screw cap over each device.

• The Water Overheating Safety Thermostat

may open if the water temperature exceeds

230 deg. F (110C) in the boiler. ONLY a faulty

Water Temperature Control causes this

shutdown. The Water Temperature Control

probably requires replacement.

• The Combustion Product Overheating Safety

Thermostat may open if combustion products

exceed 250 deg. F (120C). This may require

adjustment of the oil burner to the proper firing

rate or cleaning the boiler and/or condenser.

After correcting any fault, either thermostat must be

manually reset by removing the screw cap on top

and depressing the reset button.

ꢀꢁꢂꢄꢁꢀ

MPI - P.O. BOX 3408 PRINCETON, NEW JERSEY 08543 - PHONE 800/524-1102 (NJ 732/329-0900) FAX 732/329-0904

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