MPI FCX Owner's manual

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1 - PRODUCT DESCRIPTION.................................................................................................................... 3
2 - DESIGNATION OF COMPONENTS ..................................................................................................... 4
3 - BOILER OPERATION............................................................................................................................ 5
4 - PRODUCT STANDARD RATINGS ....................................................................................................... 6
5 - DIAMETER OF PIPE CONNECTIONS.................................................................................................. 6
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1 - OPENING THE UNIT............................................................................................................................. 7
2 - LOCATION OF THE UNIT..................................................................................................................... 7
3 - FLUE CONNECTIONS AND ROUTING................................................................................................ 8
4 - CONDENSATE DRAIN CONNECTION............................................................................................... 13
5 - WATER CIRCUIT CONNECTIONS..................................................................................................... 14
6 - FUEL OIL SUPPLY CONNECTIONS.................................................................................................. 15
7 - ELECTRICAL CONNECTIONS........................................................................................................... 16
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1 - PRE-START FINAL SYSTEM CHECK................................................................................................ 18
2 - START-UP AND OPERATION............................................................................................................ 18
3 - ADJUSTING THE OIL BURNER ......................................................................................................... 19
4 - CHECKING THE SAFETY DEVICES.................................................................................................. 19
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1 - CLEANING THE BOILER SHELL........................................................................................................ 20
2 - CLEANING THE CONDENSER .......................................................................................................... 20
3 - BURNER MAINTENANCE................................................................................................................... 21
4 - ADDITIONAL COMPONENT MAINTENANCE.................................................................................... 21
5 - EXPANSION TANK PRE-INFLATION PRESSURE CHECK............................................................... 21
6 - COMBUSTION PRODUCT FLUE........................................................................................................ 21
7 - CHANGING A THERMOSTAT OR THE THERMOMETER................................................................. 22
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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).
Model 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 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.
• Complete internal air piping terminating in a
connection to a coaxial flue/combustion air in-
take system.
Standard options include:
• Coaxial balanced flue system components for
connection to the boiler to provide venting of
the flue products and combustion air intake.
8.94
17.7
34.0
34.4
2.28 5.98 5.55
2.20
2.20
34.6
34.4
27.523.7
39.1
Front view Side view Rear view

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Front view
View from above
Rear view

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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.
Circuit heating
return or
2nd circuit heating
output
1st circuit heating
output

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Ratings for Model FCX are provided in the following
table:
Ratings are for the boiler when connected to stan-
dard option coaxial flue system components.
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Rated Output BTUH 76,000
Rated Input BTUH 81,250
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
Maximum Heating Service Pressure Psig 43.5
Max Heating circuit water temperature 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 0.22
Packaged Weight Lb. 267
Electrical Power Supply 115 volts, single phase, 60 Hz
Full Load Current 3.0 Amps FLA
Max Fuse/ Circuit Breaker Size 15 Amps
&RQQHFWLRQ 'LDPHWH 8QLWV
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 ½ Inch
Air Bleed 3/8 Inch
Safety pressure relief valve 3/4 inch

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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.
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
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).
2
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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.
Various standard option flue piping components and
packages with which to create the flue system are
available.
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Useful length under sleeve tile - 16.9 inches
(0.43 m)
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Useful length after assy. - 17.7 inches (0.45 m) or
37.4 inches (0.95 m)
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N40.28399 38.6 inches
(980 mm)
5HIH HQFH V72.28414
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(1080mm) 3.15 inch (80mm) 4.92 inch (125mm)
N40.28394 Black 42.5inches
(1080mm) 3.15 inch (80mm) 4.92 inch (125mm)
5HIH HQFH /HQJWK ,' 2'
N40.28397 19.7 inches
(500 mm) 3.15 inch (80mm) 4.92 inch (125mm)
N40.28398 39.4 inches
(1000 mm) 3.15 inch (80mm) 4.92 inch (125mm)

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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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N40.12165 25 - 45 deg Tile Tile
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N40.28396 90 deg 3.15 inch
(80mm) 4.92 inch (125mm)
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The flue/combustion air system piping may be either
horizontal or vertical or a combination of both, ob-
serving the following:
• The maximum unrestricted horizontal or verti-
cal flue length shall not be more than 16.4 ft
(5 m).
• 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.
• 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.
• 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.
• 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).
All flue-piping components must be assembled 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 illustra-
tion that follow.
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Option: Straight Horizontal Flue Kit
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Option: Angled Horizontal Flue Kit
40 cm
mini
30 cm
mini
16 In.
- 12 In.
1,80 m
5.9 ft.
1 in
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Options:
- 1 90 deg concentric elbow
- Concentric extensions
- 1 concentric vertical terminal
- 1 sleeve tile roof flange
- 1 roof plate
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
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Options:
- 1 45 deg concentric elbow
- 1 90 deg concentric elbow
- Concentric extensions
- 1 concentric vertical terminal
- 1 sleeve tile roof flange
- 1 roof plate
Options:
- 1 90 deg concentric elbow
- 3 Concentric extensions
- 3 45 deg concentric elbows
- 1 concentric vertical terminal
- 1 sleeve tile roof flange
- 1 roof plate
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rear boiler
View from above
45° elbow
90° elbow
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rear boiler
View from above
45° elbow
90° elbow

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Options:
- 1 45 deg concentric elbow
- 2 90 deg concentric elbow
- 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 theunit 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.
1,80 m
5.9 ft
1 in
rear boiler
view from above
45° elbow
90° elbow
56
7
8

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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:
• 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.
• 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.
• 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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Various typical water circuits (cont)
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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).
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-
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 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.
White
Blue
Grey
Brown
Black
Orange
Red
Dark green
Light green
W :
B :
Gy :
Br :
Bk :
O :
R :
Dk. G :
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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.
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.
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.
1
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Before starting normal operation of the boiler and
heating system, perform the following final installa-
tion procedures:
• Leak-check the flue/combustion air system to
minimize the likelihood of leakage.
• Leak-check the entire water system, repairing
any leaks that may be found.
• Fill the entire water system with water, treated
as desired for the application, including anti-
freeze solution if appropriate. Open any shut-
off valves in the system.
• Fill the condensate drain trap with water.
• Leak-check the fuel oil supply system and
open any fuel shut-off valves.
• Re-check the power and control circuit con-
nections THEN replace all cabinet access pa-
nels.
• 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.
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.
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)
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.
16
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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 :
- 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,
- 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,
- Safety Pressure Relief valve :
• Check the safety pressure relief valve in the
heating circuit for proper operation.
6
7
7
6
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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.
  &/($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.
B
B
C
B
C
B
E
14
14
D
P
G
F
4
F
G
I
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