Service manual

2
FCX INSTALLATION AND SERVICE MANUAL
FCX INSTALLATION AND SERVICE MANUAL
TABLE OF CONTENTS
I. INTRODUCTION
1 - PRODUCT DESCRIPTION
Model FCX oil fired heating system 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
heating system 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
heating system, 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-HEATING SYSTEM 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 ................................ 13
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 SYSTEM 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 A THERMOSTAT OR THE ..................
THERMOMETER ...................................................16
V - OPERATING ............................................................... 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 .............................. 45
Standard options available from Monitor include:
• Coaxial balanced flue system components for connection to
the heating system to provide venting of the flue products and
combustion air intake.