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Monitor FCX & DHW Owner and Service

1. 13 1 PRE START FINAL SYSTEM CHECK 13 2 START UPAND OPERATION 13 3 ADJUSTING THE OIL BURNER 14 4 CHECKING THE SAFETY DEVICES 14 IV MAINTENANCE enint u u 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 EE 15 6 COMBUSTION PRODUCT FLUE 16 7 CHANGING A THERMOSTAT ORT THE THERMOMETER dedu 16 V OPERATING FAULLTS 16 VI MONITOR PRODUCTS INC MPI LIMITED WARRANTIES eebe 17 VI 18 Vill HEAT WISE BURNER 21 1 BURNER WARRANTY 21 2 OPERATING INSTRUCTIONS 22 3 SERVICING THE BURNER 24 4 WIRING DIAGRAM eene 26 5 PARTS BREAKDOWN 28 6 HONEYWELL CONTROLS 30 PUMP paseri E Dega 44 8 BS INDIRECT
2. 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 Gal hr 254 Water Pressure Drop at nominal flow rate MCE 1 4 Power Absorbed with burner without circulator KW Packaged Weight Lb 0 2 267 Ratings are for the boiler when connected to standard option coaxial flue system components Electrical Power Supply Full Load Current Max Fuse Circuit Breaker Size 115 volts single phase 60 Hz 2 0 Amps FLA 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 1 OPENING THE UNIT To open Model FCX to access for installation and or service follow these steps e Remove the contr
3. Delay Timings DIP Switch Settings xween Valve On Delay Burner Motor Off S 3 Enable ECHT seconds Delay minutes Disable R7184U R7184P 5 1 S 2 R7184U R7184P 0 0 X X Off b 15 0 0 5 Off Off On 2 2 Off On ho a 4 On Off 6 8 On On 100 X Don t Care e Ke SOLDERLESS gt gt 1 4 IN QUICK Specific models may have different timings Be sure to check UN SERIAL WIRE CONNECTOR CONNECT TERMINAL device label POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED FEATURE ON SELECT MODELS PAN REFER TO DEVICE LABEL FOR WIRE COLOR CODE AN ENVIRACOM TERMINAL 3 IS ALSO THE FIRST THERMOSTAT TERMINAL b S 3 not provided on R7184P models Table 3 Cad Cell Resistance When Sensing Flame Flashes Cad Cell Resistance in ohms 1 1 than 400 Fig 10 Typical wiring diagram for line voltage Aquastat thermostat and R7184P U for valve on delaylburner motor 2 More than400 and less than 800 off delay oil burner system 3 More than 800 and less than 1600 LED 4 More than 1600 and less than 5000 CEP 80030 17 1600 ohm cad cell resistance reading 3 flashes LED VALVE ON DELAY TIME 15 SEC FIXED BURNER MOTOR OFF DELAY TIME i DELAY TIMES R7184U OMIN 2MIN 4MIN MIN ENABLED DISABLED R7184P DSMIN 2MIN 4MIN SHADED AREA IS SWITCH HANDLE POSITION SELECT MOD
4. 2 Make sure system is powered Check circuit breaker or fuse 1 80 k i and close system switch if provided 3 Set thermostat to call for heat LEGEND Z SCREW TERMINAL 1 4 IN QUICK CONNECT TERMINAL 4 Make sure burner lights and operates until call for heat ends Check Safety Features Safe Start 4N POWER SUPPLY PROVIDE DISCONNECT MEANS 1 Place a jumper across cad cell terminals AND OVERLOAD PROTECTION AS REQUIRED 2 Follow procedure to turn on burner Burner must not start OPTIONAL FEATURE ON SELECT MODELS indicator light turns on and control remains in Idle Mode VALVE MAY BE ADDED AS SHOWN Simulate flame failure Fig 4 Typical wiring diagram for 24 Vac thermostat and R7184 1 Follow procedure to turn on burner HI for an oil fired forced air system Close hand valve in oil supply line Device enters recycle mode R7184 Device tries to restart system after approximately 60 seconds a N Safety switch locks out approximately in safety switch timing indicated on label Indicator light flashes at 1 Hz rate Ignition and motor stop and oil valve closes L8148A C 1 AQUASTAT CONTROLLER B THERMOSTAT BURNER MOTOR A INTERRUPTED IGNITOR POWER NTERM d A SUPPLY I 1571 PROVIDE echt e DISCONNECT I CIRCUIT CELL MEANS AND E L B OVERLOAD MK BURNER MOTOR ee PROTECTION LEGEND 2 SCREW TERMINAL gt 1 4 IN QUICK CONNECT TERMINAL AS REQUIRED INTERRUPTE
5. valve I Max nozzle Max nozze Maximum one MODEL capacity GPH RPM MODEL capacity GPH RPM pipe H lift 8 Ft at 100 PSI at 100 PSI A2V 2000 3 3450 B1V 8200 3 1725 A1V 7100 3 1725 B2V 8200 3 3450 A2V 7100 3 3450 B1Y 8900 7 1725 A2V 7400 3 3450 B1Y 8900 7 3450 A1Y 7900 7 1725 A2Y 7900 7 3450 The Suntec Model A Fuel unit may be installed one pipe with gravity feed Lift Strainer UL Strainer Rating GPH Designator Rotatior Nozzle Location The maximum allowable lift is 8 ft See Figure 4 Type 2 Fue A RH RH Important One pipe installations must be absolutely air tight or V 3 B RH LH leaks or loss of prime may result Bleed line and fuel unit com Y 7 C LH LH pletely Bleed for 15 seconds after last air is seen from easy flow to T 23 D LH RH be certain lines are air free G 34 L Line Length in Feet H Head in feet Q Firing rate GPH 3 8 line L 6 75H 1 2 Line L 6 75H 0086 Q 00218 Q If tank is above pump change to Fittings valves and filters will reduce total length allowed TWO PIPE SYSTEM MODEL A AND B Max firing rate not to exceed max nozzle capacity or strainer rating whichever is LESS A greater firing rate requires a suitable external strainer ALL INSTALLATIONS SHOULD BE MADE WITH LOCAL AND NATIONAL CODES A SINGLE STAGE TWO PIPE MAX LINE LENGTH H R Outside tank fuel unit Lif 5 SEM SSH SM abo
6. Monitor FCX INSTALLATION AND SERVICE MANUAL Monitor Propucts INc P O Box 3408 Princeton NJ 08543 www monitorproducts com 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 Revised January 21 2010 As part of its policy of continuous product improvement Monitor Products Inc reserves the right to make changes without notice FCX INSTALLATION AND SERVICE MANUAL FINTRODUCTION ere eects 2 PRODUCT DESCRIPTION 2 2 DESIGNATION OF COMPONENTS 3 3 4 PRODUCT STANDARD RATINGS 4 5 DIAMETER OF PIPE 4 TINS TA EATON iiss ce 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 FUELOIL SUPPLY CONNECTIONS 13 Ill START UP AND OPERATION
7. When flame is not established during Trial for Ignition When flame is lost three times in one call for heat When flame is detected during burner motor off delay period Diagnostic LED The diagnostic LED has four states On Flame present Off No flame Two seconds on two seconds off Recycle 1 2 second on 1 2 second off Lockout Cad Cell Resistance Cad cell resistance can be checked without using an ohmmeter During the run mode press and release the reset button The resulting flashes indicate the resistance See Table 3 Valve on Delays Blower Motor off Delays Select models may have fixed or selective delays for valve open or blower motor off The safety circuits will check for flame during these delays and if a flame is present will switch the control to lockout SPECIFICATIONS Models Table 1 lists the major features and the applicable wiring diagram numbers for the R7184 Timing Safe Start Check 5 seconds approximately Valve on Delay 15 seconds Burner motor off Delay 0 2 4 or 6 minutes Field selectable using dual inline programmable DIP switch positions 1 and 2 Select models have 0 5 2 4 or eight minute delays See Fig 2 NOTE For universal R7184U model valve on delay and burner motor off delay timings can be enabled values as listed or disabled values are zero in the field using DIP switch position 3 Lockout 15 30 or 45 seconds factory programmed Recycle
8. 4 1 Air adjustment is set at the factory Graduations are number from 1 to 32 on the air adjustment dial see Fig 5 By turning the air adjustment screw clockwise the air shutter opening increases The air adjustment dial is set between 6 and 7 To achieve proper combustion the air shutter may need to be adjusted so that combustion analysis achieves 11 5 to 13 5 CO2 or 2 to 4 O2 5 NOZZLE LINE HEATER The burner comes with a true nozzle line heater It is wired in series to the Honeywell microprocessor control R 7184 P There is an initial delay while the nozzle line heater brings the oil to the proper operating temperature Once the oil reaches the proper temperature the burner control will receive power See Fig 6 wiring diagram HEAD SETTING Cap 23 x FIG 3 Adjustment of nozzle Assembly 0 22 FIG 5 AIR ADJUSTMENT Air Adjustment 0 22 www monitorproducts com HEAT WISE BURNER FIG 6 NOZZLE LINE HEATER WIRING A Black 3 Blue 2 Brown L U Yellow green d o 6 FUEL PUMP 6 1 A standard fuel pump is used on the Pioneer burner Therefore it is important that discharge pressure is monitored very closely It is recommended that a 10 micron filter with a vacuum gauge be installed before the fuel pump using a flexible oil line the flexible oil line is recommended to easily service the burner between the fuel pump and filter 6 2 The fuel pump on the burn
9. 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 FCX INSTALLATION AND SERVICE MANUAL Standard options available from Monitor include Coaxial balanced flue system components for connection to the boilerto provide venting of the flue products and combustion air intake T Ir 34 4 INTRODUCTION 2 DESIGNATION OF COMPONENTS 1 Control Panel Valve 4 Condenser 8 Condensate Drain 2 Control Panel Cover 3 Safety Pressure Relief 5 Manual Mixing Valve 6 Combustion Product Pressure Test Point Condenser Inspection Port fav l4nY laai Pos 99 0 Ge 9 25 227 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 S o Thermostat EM 16 Heating Output Sensor 17 Bleed Connection 18 First Circuit Heating Output Rear View 3 BOILER OPERATION 27 2000 tepuit OAPI Ss ae N ct ia C2 m NY Vire 4 dE e e Front View 19 Second Circuit heating output 20 Combustion Products Flue x 21 First Circuit Heating Return 22 Second Circuit Heating
10. terminals after burner motor turns on Indicator light is on Replace cad cell bracket assembly Refer to TRADELINE Catalog for bracket part numbers Indicator light is off Replace R7184 Home and Building Control Honeywell Honeywell Plaza 155 Gordon Baker Road P O Box 524 North York Ontario Minneapolis MN 55408 0524 M2H 3N7 Home and Building Control Inc Honeywell Limited Honeywell Limit e R7184A B B U INTERRUPTED ELECTRONIC OIL PRIMARY Printed in U S A on recycled paper containing at least 10 post consumer paper fibers R7184A B P U Series 5 Interrupted Electronic Oil Primary EnviraCOM Enabled U S Registered Trademark Copyright 2005 Honeywell International Inc All Rights Reserved INSTALLATION INSTRUCTIONS APPLICATION The R7184A B P U Interrupted Electronic Oil Primary is a line voltage safety rated interrupted ignition oil primary control for residential oil fired burners used in boilers forced air furnaces and water heaters The R7184A B P U used with a cad cell flame sensor operates an oil burner and optional oil valve The primary controls fuel oil senses flame controls ignition spark and notifies a remote alarm circuit when in lockout The R7184 can be used with both hydronic and forced air systems When used with hydronic systems line voltage switching Aquastat Controllers normally provide for the starting and stopping of the combustion sequences
11. 100 100 16 3 2 27 100 100 2r 24 100 100 18 22 88 14 76 65 www monitorproducts com BS DOMESTIC WATER HEATERS INSTALLATION INSTRUCTIONS BS DOMESTIC WATER HEATERS DESCRIPTION These domestic water heaters consist essentially of Austenitic stainless steel tank and coil Polystyrene insulation easy to remove from the tank ABS plastic casing Inspection trap Thermometer and temperature setting aquastat Connector Il INSTALLATION ELECTRICAL CONNECTIONS Provision must be made for fitting a pressure relief valve to limit the domestic water pressure to 100 PS I 7 bars and a domestic water expansion vessel or a French standard domestic water safety unit to carry out the functions of pressure relief valve non return valve towards the cold water circuit expansion vessel drain and stop valve Never mount a shut off valve between the safety unit or the pressure relief valve and the tank Connect the safety unit up to the effluent water drain Make sure that the maximum primary circuit pressure doesn t exceed 140 PSI 10 bars on the maximum pressure of the heat generator if less than 140 PSI 10 bars If the domestic hot water tank has been selected to provide maximum performance make sure that the output and primary circuit temperature are correct and that the generator power is at least equal to the exchanger power When the cold wate
12. 15M 76400 18 2356 FUSE 6 3AMP 5X20 13 2352 SAFETY THERMOSTAT 120 CAP 2558 WIRING FOR FOX 1 5M TG400 2359 ELECTR CONTROL BOX CABLE FCX INSTALLATION AND SERVICE MANUAL AMPI 20 NOT SHOWN ON THE DRAWING HEAT WISE BURNER VIII HEAT WISE BURNER Heat Wise Inc 1528 Rocky Point Road Middle Island NY 11953 LIMITED WARRANTIES FOR OIL AND GAS BURNERS MADE BY HEAT WISE AND USED IN INSTALLATIONS HEAT WISE INC Heat Wise warrants to those who purchase its Oil Burner Models for resale or for incorporation into a product of resale that its burner is free from defects in material and workmanship under normal use and service for thirty six 36 months from the date of manufacture ALL GAS BURNERS manufactured by Heat Wise will be similarly warranted for thirty six 36 months from the date of manufacture except where original manufacturer offers a greater warranty Reference 6 below THESE LIMITED WARRANTIES DO NOT APPLY UNLESS THE BURNER COVERED BY IT IS PROPERLY INSTALLED BY A QUALIFIED COMPETENT TECHNICIAN WHO IS LICENSED WHERE STATE AND OR LOCAL CODES PREVAIL AND WHO IS EXPERIENCED IN MAKING SUCH INSTALLATIONS IN ACCORDANCE WITH NFPA 31 OF THE NATIONAL FIRE PROTECTION ASSOCIATION AND INACCORDANCE WITHALL LOCAL STATE AND NATIONAL CODES Any IN WARRANTY burner component which is defective in material or workmanship will be either repaired or replaced as follows 1 Fuel units motors transformers gas va
13. Fig 4 Alarm terminals Press the two buttons on the top of the terminal insert wires and release buttons HONEYWELL CONTROL AQUASTATS CONTROLLER ENVIRACOM TERMINAL em emm 9 emm LEGEND Z SCREW TERMINAL A gt 1 4 IN QUICK CONNECT TERMINAL SOLDERLESSWIRE CONNECTOR AN POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED OPTIONAL FEATURE ON SELECT MODELS REFER DEVICE LABEL FOR WIRE COLOR CODE IS ON SPECIFIC MODELS A SEE FIG 2 4 ENVIRACOM TERMINAL 3 IS ALSO FIRST THERMOSTAT TERMINAL Fig 5 Wiring R7184P U without EnviraCOM for typical oil fired boiler AQUASTAT amp CONTROLLER ENVIRACOM TERMINAL IGNITOR ccu LEGEND 2 SCREW TERMINAL A gt 1 4 IN QUICK CONNECT TERMINAL SOLDERLESSWIRE CONNECTOR POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED OPTIONAL FEATURE ON SELECT MODELS REFER TO DEVICE LABEL FOR WIRE COLOR CODE VALVE IS OPTIONAL ON SPECIFIC MODELS AN ENVIRACOM TERMINAL 3 IS ALSO THE FIRST THERMOSTAT TERMINAL Fig 6 Wiring R7184 with EnviraCOM connections for typical oil fired boiler Cap 39 CTDBBB OUTDOOR TEMPERATURE SENSOR HOT STSTEM TRANSFORME ITO REMOTE ALARM CIRCUIT LEGEND Z SCREW TERMINAL 3 gt 119 IN QUI
14. Flush 6 120 Fan with end cone Servicing of the Pioneer 1 on the FCX Boiler Pioneer 1 Burner with FV head for condensing Boiler Note head setting at 1 75 and air setting 6 Do not change the head setting Air setting may need adjustment FCX INSTALLATION AND SERVICE MANUAL Cap 24 Burner head flush with end cone Use a 4 mm Allen key HEAT WISE BURNER Use 3 mm Allen key to remove flame tube loosening set screws on both sides Pull out the flame tube and take precautions to ensure O ring is not damaged or Ss lost to loosen the retention head Then separate the retention head from the oil line Use two 5 8 wrenches or one wrench and the given nozzle wrench to nozzle Proceed with reverse process to reinstall the burner after changing the old nozzle with a new 0 5 X 800 AS nozzle Removing the air guide E RECORD THE READINGS DATE INSTALLER NOZZLE NOZZLE NOZZLE NOZZLE SIZE GPH MANUFACTURER LYPE ANGLE PUMP DRAFT IN THE SMOKE STACK PRESSURE BREECH wc TEMPERATURE PSI CARBON DRAFT OVER DIOXIDE or FIRE wc OXYGEN api 25 www monitorproducts com HEAT WISE BURNER w 9 s i m 1 L _ L j Fig 7 Wiring Diagram VACUUM HOLD TEST If the flame misfires and or the pump is noisy After firing the burner a vacuum hold test must be perf
15. GLASS FIBER INSULATION LG 950 CAST PLATE 14 2306 CERAMIC FIBER INSULATION D 280X20 300 C 15 2372 BOILER SHELL COVER CAST IRON 16 2307 TOP COVER EQUIPPED 17 2308 PROTECTING COVER 18 2309 ABS PROTECTION 19 2359 ELECTR CONTROL BOX CABLE 20 2373 CONDENSER COVER 21 231 TOP RING CONDENSER 22 2312 FASTENING FLANGE FOR CONDENSER COVER 23 2364 CONDENSER secondary heat exchanger 24 2313 SEAL AFM34 D 18 6 X 12 2 MM THICKNESS 25 2360 BRASS CONNECTION M1 2 F3 4 NPT 26 2314 LEFT HAND SIDE COVER EQUIPPED 27 2315 INSULATION LEFT HAND SIDE 28 2316 NITRILE O RING D 50X4 70 SHORE 29 2376 CLEANING CAP FOR CONDENSER EQUIPPED 30 2377S HEATING RETURN 2 CIRCUIT SHORT 31 2317 SEALING AFM34D 30X21X3 32 2377L HEATING RETURN 1 CIRCUIT LONG 33 2378 HEATING FLOW 2 CIRCUIT 34 2318 SEALING ON CONDENSER FLANGE 35 2379 HEATING FLOW 36 2380 BOILER SHELL RETURN 37 2381 MALE CONNECTION 3 4 38 2363 ADAPTOR FOR VENTOUSE D 80 125 39 2319 SILICONE SEALING D 162X85X4 40 2320 BLACK HANDLE FOR H3MG VALVE 41 2321 REDUCED MESSING NIPPLE M1 M3 4 42 2322 NUT 43 2323 BRASS VALVE 44 2324 NUT FOR FLANGE 1 FOR PIPE D 22 5 45 2325 STAINLESS STEEL WASHER 30 4X25 5X0 3 46 2326 SIGHTGLASS PYREX D 30X5 4 9012 EXPANSION TANK VESSEL 8L MALE 3 4 48 2327 SEALING AFM34 D 24X17X3 49 2328 DRAIN VALVE WITH CAP M 1 2 M 3 4 50 2389 HEATING FLOW B
16. INSTALLATION INFORMATION FOR A 2000 A 7000 SINGLE STAGE AND B 8000 TWO STAGE FUEL UNITS 3450 RPM WHITE LABEL Read operating 1725 RPM BLACK LABEL Read operating Dressure Pressure gage pressure Nozzle port 1 8 port 1 8 Nozzle port 1 8 Figure 2 Figure 1 Regulate Regulate pressure pressure Inlet 1 4 Inlet 1 4 Easy Flow Air Bleed Easy Flow Air Bleed Gage Port e Gage Port Inlet 114 Return 1 4 Return 1 4 i Model B two stage 1 16 by pass plug insert fuel unit has same 1 16 by pass plug insert for 2 pipe system use 5 porting arrange for 2 pipe system use 5 32 allen wrench ment as Model A 32 allen wrench ONE PIPE SYSTEM Figure 4 DO NOT INSTALL BY PASS PLUG Connect inlet line to pump inlet Start burner Arrange primary burner control for continuous operation during purging Open easy flow bleed valve 1 turn CCW Bleed unit until all air bubbles disappear HURRIED BLEEDING WILL IMPAIR EFFICIENT OPERA TION OF UNIT Tighten Easy flow bleed valve securely TWO PIPE SYSTEM Figure 5 REMOVE 1 16 BY PASS PLUG FROM PLASTIC BAG AT TACHED TO UNIT Remove 1 4 plug from return port In sert by pass plug See figure 1 or 2 Attach return and inlet lines Start burner Air bleeding is automatic Opening Easy Flow Air Bleed Valve will allow a faster bleed if desired Re turn line must terminate 3 4 above supply line inlet 596 Fi
17. Return 23 Well for Combustion Product Overheating Thermostat Bulb 24 Protection Plate for Electrical Connections Box 25 Circulating pump 26 Expansion vessel Combustion air is drawn into the oil Circuit burner by the burner fan through the heating air intake hose connected to the jer bum coaxial flue combustion air intake beste exhaust separator Heated air from output 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 www monitorproducts com INTRODUCTION INSTALLATION 4 PRODUCT STANDARD RATINGS Ratings for Model FCX are provided in the following table
18. hand valve in oil supply line 2 Make sure system is powered Check circuit breaker or fuse and close system switch if provided 3 Set thermostat to call for heat 4 Make sure burner lights and operates until call for heat ends 5 Verify that burner turns off when thermostat call for heat is satisfied Check Safety Features Safe Start 1 Place a jumper across cad cell terminals 2 Follow procedure to turn on burner Burner must not start indicator light turns on and control remains in Idle Mode Simulate Flame Failure 1 Follow procedure to turn on burner Close hand valve in oil supply line Device enters recycle mode Device tries to restart system after approximately 60 seconds a amp o N Safety switch locks out approximately in safety switch timing indicated on label Indicator light flashes 1 2 second on 1 2 second off Ignition and motor stop and oil valve closes Simulate Ignition Failure 1 Follow starting procedure to turn on burner but do not open oil supply hand valve 2 Observe that safety switch locks out approximately within safety switch timing as indicated on the label Indicator light flashes 1 2 second on 1 2 second off Ignition and motor stop and oil valve closes DIAGNOSTIC LED ENVIRACOM DATA PORT CONNECTOR ENVIRACOM TERMINALS Fig 2 R7184 terminals connectors LED reset button and DIP switch locations Fig 3 R7184 wiring connections
19. in 10 min at 40 C storage 65 C litres 169 241 313 476 Volume drawn in 1 hour at 40 C storage 65 C litres 702 774 846 1009 Cold water inlet 10 C Primary boiler water temperature set 80 C Reheating time in minutes after a 10 mn drawn Max hot water tapping at continuous domestic water flow IV WALL MOUNTING Wall mounting bracket for BS 100 BS 150 EBS 100 and EBS 150 V CHECK THE ANODE The anode must be checked once a year solate the cold water supply in to installation by using a stop valve Drop the pressure inside the WW tank by opening a hot water tap 47 e Unscrew the anode Check the degree of corrosion stage of the anode If its weight is under 150 g replace it with a new one Replace the sealing joint and screw in the new anode Open the water supply in the installation Anode JN VI RELIEF VALVE A temperature and pressure relief valve listed as complying with the Standard for Relief Valves and Automatic Gas Shut off Devices for Hot Water Supply Systems ANSI Z21 22 shall be installed at the time of installation of the heater in the locations provided or specified by the manufacturer Local codes shall govern the installation of such relief devices For safe operation of the water heater the relief valve s must not be removed or plugged Pressure relief valve must be manually operated at least once a year Precautions must be taken p
20. spark for 10 to 30 seconds a Turns on indicator light b If flame is lost and lockout time has not expired R7184 returns to Trial for Ignition period c If flame is lost and lockout time has expired R7184 enters Recycle Mode AMPI 41 www monitorproducts com HONEYWELL CONTROL Table 4 R7184 Operation continued External Action R7184 Action Thermostat or Aquastat Control calls for heat 6 Carry Over time expires ignitor turns off 7 Enters Run Mode a Flame is monitored until call for heat ends or flame is lost If flame is lost 1 Control enters Recycle Mode 2 Recycle time starts 60 seconds 3 Burner and valve are turned off 4 Indicator light flashes at 2 seconds on 2 seconds off 5 Returns to Idle Mode at end of Recycle Mode Call for heat is satisfied 1 R7184A U if burner motor off delay is disabled a Burner motor and oil valve shut off b Indicator light turns off 2 R7184B P U if burner motor off delay is enabled a Oil valve shuts off b Burner motor runs for selected burner motor off delay time c Burner motor turns off d Device returns to Idle Mode Reset Button pushed two times without device completing a call 1 R7184 enters Restricted Mode 2 Indicator light flashes and 1 2 second on 1 2 second off for heat 3 Reset device by pressing and holding reset button for a minimum of 30 seconds Table 5 Troubleshooting Info
21. until the oil gets back to a temperature of 125 130 F PHONE 732 329 0900 FAX 732 329 0904 MPI offers technical support to qualified licensed heating contractors during normal business hours Monday Friday 8 30 A M to 4 30 P M Eastern Time To help us serve you properly our technicians will require the following information Nozzle manufacturer G P H angle and pattern Pump pressure in PSI Pump vacuum in inchs of Hg Oil delivery system 1 pipe or 2 pipe Oil Tank Indoor outdoor Above or below pump level Smoke reading COreadinginPPM CO 2 reading in Flue Outlet Temperature F Water Outlet temperature F Water Return temperature F System load Radiant high temperature DHW Total BTU requirement WARRANTIES VI MONITOR PRODUCTS INC MPI LIMITED WARRANTIES First year MPI warrants that its FCX boilers are free from defects in material and workmanship under normal use and service for 1 year from the date of purchase with an additional period of up to 3 months if the unit is not installed at time of purchase First through tenth year MPI warrants that the primary heat exchanger is free from defects in material and workmanship for 10 years from date of purchase Parts covered All product or parts of the FCX manufactured by or for MPI except as provided for herein Parts not covered The following parts are not covered by this warranty venting kits fuses and all parts subje
22. 0 60C 4 Water Outlet Temperature Thermometer Circuit 1 5 Water Overheating Safety Thermostat Burner Cutout 6 Combustion Product Overheating Safety Thermostat Boiler Shutdown 7 Burner Safety Device Light 8 Slot for Additional Control Note overheat thermostats may not physically pop up if tripped Press the red center with a pointy object such as a pen and listen for an audible click Fig 42 Ae 4 gt CED 4 x j e a gt O O EA FCX 44 0 START UP AND OPERATION To start the boiler first make sure the room thermostat 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 Control 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 3 ADJUSTING THE OIL BURNER While the oil burner leaves the factory set at the recommended settings safe operation requires that the burner be checke
23. 1 sleeve tile roof flange 1 roof plate Adjustable supports as needed max L L1 3 28 ft 1m lt 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 max L L4 1 64 ft 0 5m L2 1 64 ft 0 5m L3 3 28 ft 1m 16 4 ft 5m Fig 19 __ condensate tee To provide clearance around water connections a View from above 45 degree we iine elbow can be rear boiler used i IMPORTANT Vertical lengths longer then 6 ft 2 meters should use a concentric condensate Tee 42255 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 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 lt 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 MPI www monitorproducts com 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 venti
24. 1764301 10195 1 10195 11417603 D82132 11859107 11852201 11851001 11848501 11912901 11987901 410005 11887001 11887301 11888101 11887801 A2VAT 116 a d a SS Ca E A CH P Scale Nozzle Assembly 11888101 MPI PART 2527 Cover Plate Air 11887001 MPI PART 2514 Scale air 11887801 MPI PART 2513 Safety Control R Plastic Cover Plate Screw Long Special Oil Nozzle Electrode Retention Head Brake Plate complete md Adjustment Screw Nozzle Assembly 11848401 1184P 11850001 11750702 DAN5AS80 11593701 11591201 FV Head 11591201 MPI PART 2550 Adjustment Screw Air Regulation 11848501 MPI PART 2511 Bushing for Adjustment Cap 28 Screws 11847901 MPI PART 2512 Electrode single 91593701 MPI PART 2521 coma BD Nozzle Line 11918902 MPI PART 2519 Flange 11811601 MPI PART 2501 Flange Gasket 11819101 Cover Plate Housing 11850001 MPI PART 2506 Long Screw 11750702 imo 1 6 HP PSC Motor D82132 MPI PART 2547 108 mm Fan 11417604 MPI PART 2515 Motor Capacitor D82132 1 MPI PART 2547 Suntec Pump A2VA7116 MPI PART 2542 Solenoid Valve SVC10FF MPI PART 2535 Fan Housing Rear 11849702 Fan Housing Front 11856902 Shielding Housing 11860801 MPI PART 2508 Cap 29 E 5 Gasket Housing 11854401 MP
25. 37 1 4 33 110 9102 78 7 2 4 33 110 Polypropylene Elbows Fig 24 Reference No Type Elbow inch mm 2259 90 3 15 80 9048 90 4 33 110 FCX INSTALLATION AND SERVICE MANUAL IPI 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 WW j E Tubing of an existing conduit A 7 negative pressure conduit 7 7 A K 7 HN 04 s Z A Oil Use Condensate Tee A E E Con 1 1 1 4 41 N d IK G Z 8 H m dl A An 777A N WK CLLLLLLLLEL LLL LLL ALLL LLL 1 m maxi Flue components gt 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 lt 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 e f you must deflect the flue system use 45 degree elbows Use 45 degree elbows instead of 90 to lessen flue restriction
26. 5 deg Tile Shingle Red 9032 25 45deg Slate Shingle Black www monitorproducts com INSTALLATION PP PVC Concentric Elbow joint fitting Fig 11 45 bend 90 bend 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 mm MPI Part 2208 3 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 125 Polypropylene Roof Plate Fig 13 Color Black Reference No MPI Part 2207 A90 12172 TYPICAL INSTALLATION EXAMPLES The flue combustion air system piping may be either horizontal or vertical or a combination of both observing the following e The maximum unrestricted horizontal or vertical flue length shall not be more than 16 4 ft 5 m if using the HeatWise burner Foreach 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 tha
27. 60 seconds fixed Ignition Carryover 10 seconds fixed Electrical Ratings Inputs Voltage 102 to 132 Vac 120 Vac nominal Current 100 mA plus burner motor valve and ignitor loads Frequency 60 Hz Outputs Relay Contacts Burner 120 Vac 10 full load amperes FLA 60 locked rotor amperes LRA Valve 120 Vac 1A Ignitor 120 Vac 360 VA Alarm 30 Vac 2A Thermostat Current Available 100 mA EnviraCOM Current Available 150 mA NOTE Reduce burner FLA rating by ignitor load For example if the ignitor draws 3A 120 Vac 360 VA reduce the burner motor FLA to 7A Typical Component Wire Color Code White Neutral Black Line Orange Blower Pump Blue or Blue w White Stripe Ignitor Violet Valve Red Limit NOTE R7184 is provided with 1 4 in 6 mm quick connect terminals Environmental Ratings Operating Ambient Temperature 40 F to 150 F 40 C to 66 C Shipping Temperature 20 F to 150 F 29 C to 66 C Humidity 90 relative humidity at 95 F 35 C noncondensing Approvals Underwriters Laboratories Inc Recognized Canadian Underwriters Laboratories Inc Table 1 R7184 Models Valve on delay Burner motor off Alarm Typical Wiring Diagram Thermostat Model sec delay min Contacts Fig reference No Terminals T T R 184A None None None 3 4 6 7 Yes R 184B 15 None None 3 4 5 8 Yes R7184P 15 0 2 4 6 or 0 5 2 4 or 8 Optional 2 3 5 8 Yes R7184U
28. CK CONNECT TERMINAL SOLDERLESSWIRE CONNECTOR POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED OPTIONAL FEATURE ON SELECT MODELS REFER TO DEVICE LABEL FOR WIRE COLOR CODE VALVE IS OPTIONAL ON SPECIFIC MODELS FACTORY INSTALLER JUMPERS ENVIRACOM TERMINAL 3 IS ALSO THE FIRST THERMOSTAT TERMINAL gt gt SPS 5 Fig 7 Typical wiring diagram for EnviraCOM enabled thermostat and R7184 for an oil fired forced air system IMPORTANT System as shown in Fig 7 is phase polarity sensitive Make sure all input power 5 in the same phase www monitorproducts com HONEYWELL CONTROL LINE VOLTAGE THERMOSTAT Ay OR AQUASTAT amp ENVIRACOM TE th cc vave Benn enee MOTOR IGNITOR gue mn c curi PUNCTION IBOX LEGEND Z SCREW TERMINAL A3 1 4 IN QUICK CONNECT TERMINAL e SOLDERLESSWIRE CONNECTOR POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED FEATURE ON SELECT MODELS ER REFER TO DEVICE LABEL FOR WIRE COLOR CODE VALVE MAY ADDED AS SHOWN PRIMARIES THAT DO NOTHAVE A VALVE LOAD GEN ENVIRACOM TERMINAL 3 IS ALSO FIRSTTHERMOSTAT TERMINAL Fig 8 Typical wiring diagram for line voltage EnviraCOM enabled Aquastat and R7184 for an oil thermostat and R7184A B for an oil burner system OPERATION The R7184 is a microprocessor based control The indi
29. D gt OPTIONAL p FEATURE ON POWER SUPPLY PROVIDE DISCONNECT MEANS lt I lt m SELECT ho Lo AND OVERLOAD PROTECTION AS REQUIRED MODELS arci OPTIONAL FEATURE ON SELECT MODELS VALVE MAY BE ADDED AS SHOWN ICIRCUIT LEGEND e SCREW TERMINAL gt 1 4 IN QUICK CONNECT TERMINAL uu Fig 5 Typical wiring diagram for line voltage Aquastat Fig 3 Wiring for typical oil fired boiler thermostat and R7184 for an oil burner system FCXINSTALLATION AND SERVICE MANUAL Pi 32 HONEYWELL CONTROL COOLING CONTROL FAN RELAY BURNER MOTOR INTERRUPTED IGNITOR INTERMITTENT 170 REMOTE tan 1 ALARM A ALARM I CELL CIRCUIT l LEGEND Z SCREW TERMINAL A gt 1 4 IN QUICK CONNECT TERMINAL 4N POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED OPTIONAL FEATURE ON SELECT MODELS Fig 6 Typical wiring diagram for 24 Vac thermostat and R7184 for valve on delay burner motor off oil burner system LINE VOLTAGE THERMOSTAT OR AQUASTATE CONTROL BURNER MOTOR INTERRUPTED IGNITOR INTERMITTENT n C REMOTE Z ALARM N ALARM CAD gt CIRCUIT CEL BURNER MOTOR JUNCTION BOX LEGEND 2 SCREW TERMINAL A gt 1 4 IN QUICK CONNECT TERMINAL VN POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED 2N OPTIONAL FEATURE ON SELECT MODELS Fig 7 Typical wiring diagram for line volt
30. EFORE 1 CIRCUIT o1 2329 CONDENSATE DISCHARGE o2 2330 AIR FLANGE D 80 LG1500 53 2331 MINERAL CARBOARD WASHER D 25X8 5X3 54 2384 INSULATION CONDENSER FCX 55 2385 BOILER SHELL COVER EQUIPPED FOR FCX 56 2332 VALVE STOP 57 2386 BASE FOR FCX 58 2387 FLANGE 59 2333 SALMSON SEALING 1 1 2 DIA 44 X 32 X 3 60 2388 CIRCULATING PUMP GRUNDFOSS 115 UPS15 42 F 9H 61 2389 BEND 90 F3 4 F 3 8 62 2334 AUTOMATIC DRAIN 3 8 WITH ISOLATING VALVE 63 2335 FLOW RETURN BEND F1 F22 64 2336 SAFETY VALVE 30 PSIG MAL FEM 3 4 NPT 65 23 4 BOILER SHELL EQUIPED 2337 SEAL VITON D 80 2338 FIXING PIECE FOR THE COVER MALE BOLT PVC BAFFLE PLATE F400 F E FEA FCX 250X200X1 5 DISK FOR ISOLATION KERLANE NOT SHOWN ON THE DRAWING PARTS BREAKDOWN FCX CONTROL BOX MPIPART DESCRIPTION 1 2340 PAINTED CONTROL BOX 2 2341 WIRE CARRIER 3 2343 WIRE ROPE CLAMP PA6 6 4 2342 TRANSFORMER 120V 24V 5 2944 PAINTED CASING CONTROL BOX 6 2345 THERMOSTAT RECT HORIZ 69X14 LG CAPIL 1500 MM 7 2346 THERMOSTAT 50 70 C SINGLE CONTACT 2347 WATER TEMP CONTROL KNOB 14 2353 UNIPOLAR SWITCH D 23 GREEN LIGHT 2357 FUSE HOLDER WICKMANN REF 19820 19835 15 2354 UNIPOLAR REVERSIBLE SWITCH D 23 BLACK 10 2349 RED LIGHT 230V 120 FLAT HEAD 16 2355 OMRON RELAY 11 2350 CONTROL PANEL STICKER 17 UPPER FASTENER FOR THE RELAY 12 2351 SAFETY THERMOSTAT 110 CAP
31. ELL CONTROL SPECIFICATIONS Models Table 1 lists the major features and the applicable wiring diagram numbers for the R7184 Timing Safe Start Check 5 seconds approximately Valve on Delay 15 seconds Burner motor off Delay 0 2 4 or 6 minutes fieldselectable using DIP switch positions 1 and 2 NOTE For universal R7184U model valve on delay and burner motor off delay timings can be enabled values as listed or disabled values are zero in the field using DIP switch position 3 Lockout 15 30 or 45 seconds factory programmed Recycle 60 seconds fixed Ignition Carryover 10 seconds fixed R7184A B BU INTERRUPTED ELECTRONIC OIL PRIMARY 69 1233 2 2 Electrical Ratings Inputs Voltage 102 to 132 Vac 120 Vac nominal Current 100 mA plus burner motor valve and ignitor loads Frequency 60 Hz Outputs Relay Contacts Burner 120 Vac 10 full load amperes FLA 60 locked rotor amperes LRA Valve 120 Vac 1A Ignitor 120 Vac 360 VA Alarm 30 Vac 2A Thermostat Current Available 100 mA NOTE Reduce burner FLA rating by Ignitor load For example if the ignitor draws 3A 120 Vac 360 VA reduce the burner motor FLA to 7A Environmental Ratings Operating Ambient Temperature 40 F 40 C to 147 F 640 Shipping Temperature 20 F 29 C to 150 F 66 C Humidity 90 relative humidity at 95 F 93 C noncondensing Approvals Underwriters Laboratories Inc Recogniz
32. ELS MAY HAVE DIFFERENT TIMINGS Fig 12 Switch settings for burner off delay times Table 4 R7184 Operation External Action R7184 Action Power applied to control Internal safety check conducted If no light or flame is detected and all internal conditions are correct control enters Idle Mode Thermostat or Aquastat 1 Shorts across T T terminals on a call for heat in warm air system and or provides power to limit Control calls for heat terminals in hydronic system Systems with EnviraCOM network may receive a call for heat on network connections 1 2 3 2 Safety Period 5 seconds internal and external check for flame or light If flame or light is detected control remains in the Idle Mode 3 When flame or light is not present a R7184A U if valve on delay is enabled will apply power to the burner motor and ignitor b R7184B P U if valve on delay is enabled will apply power to the burner motor and ignitor enter complete valve on delay period and then apply power to the valve 4 Control enters Trial for Ignition period a Monitors burner for flame b When flame is not detected 1 Enters lockout mode after lockout time of 15 30 or 45 seconds 2 Shuts off valve ignitor and burner motor 3 Flashes indicator light at 1 2 second on 1 2 second off 4 Depress reset button to return to power up sequence c When flame is detected Carry Over period begins 5 Control enters Ignition Carry Over period continues to
33. I PART 2507 Bushing 11847901 MPI PART 2512 Outside Air Boot 11859107 MPI PART 2531 9m ow Gasket Air Boot 91859107 MPI PART 2533 a Air Regulation Plate 11852201 MPI PART 2509 Air Damper 11851001 MPI PART 2510 HEAT WISE BURNER Weiland Plug Female 11558608 MPI PART 2518 Weiland Plug Male 11558500 MPI PART 2504 O Ring 11516935 Air Distributor 11852201 Nozzle DAN5AS80 MPI PART 2541 110 V Igniter 41000S MPI PART 2540 www monitorproducts com HEAT WISE BURNER HONEYWELL CONTROL Cd Cell Bracket 4074BJS MPI PART 2549 Oil Safety Control R7184P MPI PART 2544 Ignition Cable 12021901 Cd Cell Wire MPI PART 2524 C554A MPI PART 2546 120320 Motor Coupler MPI PART 2546 V1409 HONEYWELL CONTROL Cd Cell Bracket Oil Connecting Pipe Electrode 12027501 Holder MPI PART 2525 439017224 MPI PART 2523 Nozzle Key 11346101 MPI PART 2503 Distance Ring Spacer 11593601 MPI PART 2522 Stud Screw Fixing Flange Flexible Oil Line 11951701 HW43006 w flange MPI PART 2539 INSTALLTATION INSTUCTIONS U S Registered Trademark R7184A B U INTERRUPTED ELECTRONIC OIL PRIMARY Copyright 2000 Honeywell Inc All Rights Reserved INSTALLATION INSTRUCTIONS APPLICATION The R7184A B P U Interrupted Electronic Oil Primary is a line vol
34. Ideas in Heating with FCX Boiler CAUTION For your safety do not store or use gasoline or other flammable vapors and liquids in the vicinity of this unit No 2 Fuel oil firing range 0 5 0 7 GPH US Units of No 1 or NO 2 oil ASTM D396 C US NY MEA 226 99 E Manufactured By Heat Wise Inc Production 1528 Rocky Point Rd Middle Island NY 11953 Note This particular manual is prepared for the FCX boiler The burner has been set and test fired to achieve optimum performance Readjustments increasing or decreasing pump pressure or nozzle size changes will change the long term performance Failure to follow the instructions in this manual will void the warranty BURNER SPECIFICATIONS Burner Burner Burner Firing Standard Nozzle and follow the steps backwards to reinstall the burner Refer Model Head Fan Range to Fig 1 for the proper electrode setting Please see pages in GPH US 6 and 7 of this manual for a pictorial on this process Pioneer 120mm 0 5 to 0 7 attachment 0 5X80 NOTE It is important to use two 5 8 wrenches to prevent 1 AS disorientation of the nozzle line heater Outside air attachment can be maximum 3 Dia X 20 nominal pipe with 4 elbows 4 NOZZLE INSTALLATION FIG 1 ELECTRODE ASSEMBLY 1 1 To service the nozzle remove the burner from the FCX boiler by unscrewing the burner mounting flange nut Using a 3 mm allen key loosen the side screw
35. ND SERVICE MANUAL MPI 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 lf 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 INSTALLATION Various typical water circuits are illustrated below L x C1 C Boiler Connection to a single nesting e circuit M Pressure gauge C1 Radiator circuit J Fare Fig 35 RE iz E Baseboards Radiant Panels SC lt or Fa
36. NTROL 4 Check contacts between ignitor and the electrodes 2 Voltmeter 0 to 150 Vac 5 Check the oil pump pressure 3 Insulated jumper wire with both ends stripped 6 Check the piping to the oil tank WARNING 7 Check the oil nozzle oil supply and oil filter Check Oil Primary Control Electrical Shock Hazard Can cause serious injury or death Troubleshoot with the system powered Be careful to If the trouble is not in the burner or ignition hardware check the observe all precautions to prevent electrical shock or oil primary control by using the following equipment equipment damage 1 Screwdriver Refer to Table 4 for further troubleshooting information Table 4 R7184 Operation External Action Power applied to control Thermostat or Aquastat R7184 Action Internal safety check conducted If no light or flame is detected and all internal conditions are correct Control enters Idle mode Control calls for heat 1 Shorts across T T terminals on as call for heat in warm air system and or provides power to limit terminals in hydronic system 2 Safety Period 4 seconds internal and external check for flame or light If flame or light is detected control remains in Idle mode 3 When flame or light is not present a R7184A U if valve on delay is disabled will apply power to the burner motor and ignitor b R7184B P U if valve on delay is enabled will apply power to the burner motor and ignitor ente
37. On cad cell is sensing flame 4 Off cad cell is not sensing flame VALVE ON DELAY TIME 15 SEC FIXED DELAY TIMES jala 113 6 MIN ENABLED DISABLED BURNER MOTOR OFF DELAY TIME 0 MIN 2 MIN SHADED AREA 15 SWITCH HANDLE POSITION M17525 Fig 8 Switch setting for burner 0ff delay times Table 2 Switch Settings and Delays Delay Timings DIP Switch Settings Valve On Delay Burner Motor Off S 3 Enable seconds Delay minutes Disable R7184U R7184P S 1 S 2R7184U R7184P 0 0 X X Off 15 0 0 5 Off Off On 15 2 Off On On 15 4 4 On Off On 15 6 8 On On On X Don t Care G A not provided on R7184P models Cad Cell Resistance Check For proper operation it is important that the cad cell resistance is below 1600 ohms During a normal call for heat once the control has entered the Run mode press and release the reset button Indicator light will flash 1 to 4 flashes See Table 3 for equivalent cad cell resistance Table 3 Cad cell resistance when sensing flame Flashes Cad Cell Resistance in ohms 1 Less than 400 2 More than400 and less than 800 3 More than 800 and less than 1600 4 More than 1600 and less than 5000 Preliminary Steps 1 Check wiring connections and power supply 2 Make sure power is on to the controls 3 Make sure limit control is closed www monitorproducts com HONEYWELL CO
38. STORAGE TANK 46 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 e A high efficiency low emission gun type oil burner with combustion air fan integral oil pump oil heater and primary control e A control panel assembly and all electrical controls for operation of the boiler including a water temperature thermometer in circuit 1 e A manual water mixing valve that can be motorized if desired e A safety pressure relief valve e An expansion tank A water circulating pump
39. Selectable 0 or 15 Selectable 0 or 0 2 4 6 Yes 2 3 5 8 Yes a Select models are provided with a T T jumper which can be disabled by cutting with a pair of side cutting pliers See Fig 2 b Some select models may have a delay enable disable switch e Standard timings Other timing may be available on select models INSTALLATION When Installing This Product make sure the product is suitable for your application 3 Make sure the installer is a trained experienced service 1 Read these instructions carefully Failure to follow instructions technician can damage the product or cause a hazardous condition 4 Use these instructions to check out the product operation after 2 Check ratings given in these instructions and on the product to installation iti Pi 37 www monitorproducts com HONEYWELL CONTROL WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before beginning installation to prevent electrical shock or equipment damage More than one disconnect may be involved Location 1 Mount on a 4 in by 4 in junction box directly on the main burner or inside the appliance cabinet In replacement applications mount in the same location as the old control See Fig 1 Make sure the operating temperatures are within the ambient temperature range see Specifications section 2 Before mounting the control make line voltage connections as sh
40. TIES described above then this portion will be added to our LIMITED WARRANTY This LIMITED WARRANTY does NOT cover products that have been damaged as the result of an accident abuse misuse neglect improper installations improper maintenance or failure to operate in accordance with HEAT WISE s written instructions These LIMITED WARRANTIES do not extend to anyone except the first purchaser at retail and only when the burner is in the original installation site IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE SHALL BE LIMITED TO THE DURATION OF THE LIMITED EXPRESS WARRANTIES CONTAINED HERIN HEAT WISE EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTIAL DAMAGES OF ANY NATURE FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANT Y Some states do not allow limitation on how long an implied warranty lasts so the above limitation may not apply to you Also some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you HEAT WISE neither assumes nor authorizes any person to assume for HEAT WISE any other liability or obligation in connection with the sale of these products This warranty gives you specific legal rights and you may also have other rights that vary from state to state AMPI 21 www monitorproducts com HEAT WISE BURNER OPERATING INSTRUCTIONS EI Waleat Wise Model PION EER 1 Bright
41. With forced air systems both mechanical and electronic low voltage thermostats control the starting and stopping of the combustion process Some hydronic and forced air systems now require a delayed valve on and burner motor off delay The R7184 operates an oil valve that prevents the flow of oil when the burner motor is running prior to combustion delayed valve on and when the burner motor is running after combustion burner motor off delay The R7184 models are intended for use only on oil burning appliances which do not require prepurge and post purge as a safety related function as defined in UL296 The valve on delay and burner motor off delay in this control are intended only to help establish draft and reduce oil after drip related problems FCX INSTALLATION AND SERVICE MANUAL Cap 36 The R7184 is EnviraCOM enabled making it compatible with EnviraCOM home networks FEATURES Thermostat s The oil primaries are compatible with both standard thermostats and EnviraCOM communicating thermostats Limited Recycle This feature limits the number of recycle trials for each call for heat to a maximum of three trials If the flame is lost three times Pump Priming Cycle To facilitate purging air from the oil lines and filters the R7184 can be placed in a purge routine by pressing and releasing the reset button during the safety check delayed valve on ignition or carry over periods The lockout timing will be extende
42. age Aquastat thermostat and R7184B P U for valve on delay burner motor off delay oil burner system Simulate ignition failure 1 Follow starting procedure to turn on burner but do not open oil supply hand valve 2 Observe that safety switch locks out approximately within safety switch timing as indicated on the label Indicator light flashes at 1 Hz rate Ignition and motor stop and oil valve closes OPERATION The R7184 is a microprocessor based control The indicator light provides diagnostic information for lockout recycling and patented cad cell status There is a manual reset button to exit the lockout mode and enter the idle mode Operation is shown in Table 4 Cap 33 TROUBLESHOOTING AND IMPORTANT Due to the potential hazard of line voltage only a trained experienced service technician should perform the troubleshooting procedure This control contains no field serviceable parts Do not attempt to take it apart Replace entire control if operation is not as described To completely troubleshoot an oil burner installation check the burner and oil primary control for proper operation and condition The indicator light on the oil primary control provides lockout recycle and cad cell indications as follows 1 Flashing at 1 Hz 1 2 second on 1 2 second off system is locked out or in restricted mode 2 Flashing at 1 4 Hz 2 seconds on 2 seconds off control is in recycle mode 3
43. an the condensate trap external NOTE If after cleaning the condenser the temperature of the flue gasses still exceeds 250 F perform a burner check Fig 41 F up ks AA Q FE um Cap 18 3 BURNER Once adjusted properly regular maintenance of the oil burner is not generally required A routine examination of the burner should include examination of the burner fan and housing for dirt and the spark electrodes for proper clearances The nozzle should be replaced after every 1000 gallons of fuel used due to wear Replace the fuel filter if necessary Cleaning and adjustment is always appropriate during periodic inspection If burner firing rate adjustment is required follow instructions in Adjusting the Oil Burner ALWAYS CHECK FOR AND CORRECT ANY FUEL LEAKS 4 ADDITIONAL COMPONENT MAINTENANCE Check to see that the safety and regulation devices safety relief valve air bleed valve control box components etc are operating properly Check that the condensate drain trap is clean If necessary remove the bottom of the trap clean it replace it and then refill the trap it with water Also check to see that neither the installation nor the boiler have any water or fuel leaks leaks may produce a risk for safety and shorten the life span If it becomes frequently necessary to add water to maintain pressure in the installation even though no leaks have be
44. at V1 Onlight V2 Burner safety shutdown light C Burner connector F J Fuse 6 3 A R Relay T Main transformer 120 24 volts CC Circulating pump Notes A Electric power leads factory provided at right rear of unit Permanently field splice 120 1 60 field provided power circuit leads in NEC junction box B Control circuit leads factory provided at right rear of the unit are 24 volt NEC class 2 for connection to a room thermostat C Do not use the internal transformer to power any external system components such as a zone valve FCX INSTALLATION AND SERVICE MANUAL box that is not provided with the unit All wiring should conform to the National Electrical Code and any applicable local codes and standards To minimize the likelihood of a heating system shutdown 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 connections are NEC Class 2 intended for connection to a typical room thermostat connection to the installation 120 o Hz earth oom L thermostat 2 wires T Cap 12 FO t op 8 EH TRC TSF wk zi C Tere Tel LLI amp lt 7 gt m so Male connec
45. at the thermostat bulbs are correctly positioned in their housings This is essential to provide temperature sensing to facilitate burner shutdown in the event of overheating Flame monitoring Check to make sure that the burner shuts down properly upon the deactivation or disconnection of the flame monitoring device or interruption of the flow of fuel Safety Pressure Relief valve Check the safety pressure relief valve in the heating circuit for proper operation IV MAINTENANCE It is recommend that the boiler and flue combustion air system be inspected and maintained annually by a qualified technician DISCONNECT ALL ELECTRICAL CIRCUITS N BEFORE SERVICING THE UNIT CLOSE ANY ISOLATION VALVES THAT MAY BE IN THE WATER SYSTEM SHUT OFF THE FUEL OIL SUPPLY IF SERVICING THE BURNER To gain access to the inside of the unit first remove the control panel cover by grasping it on both sides and pulling FCX INSTALLATION AND SERVICE MANUAL Cap 14 directly outward towards you and up Remove any front panel screw s and remove the front panel by pulling the top out towards you and then lifting up to free the bottom from the mounting 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 th
46. ate sales invoice or cancelled check showing the serial number as satisfactory evidence Any replacements are made subject to validation by MPI of in warranty coverage An item to be replaced must be made available in exchange for the replacement SOLE REMEDY The remedy and liability for any breach of warranty express or implied set forth herein is the sole and exclusive remedy and the limit of liability for any such breach EXCLUSIONS AND IMPLIED WARRANTIES This warranty does not extend to any defect due to the negligence of others Failure to install operate or maintain the product s in accordance with the installation operation and maintenance instructions furnished with each new product unreasonable use accidents acts of god fire snow floods lightning alteration ordinary wear and tear or the use of unauthorized or non standard parts ALL IMPLIED WARRANTIES IF ANY ARISING UNDER LAW IN CONNECTION WITH THE SALES BY MPI OF ANY PRODUCT S ARE LIMITED IN EXTENT AND DURATION TO THE DURATION OF THIS WRITTEN WARRANTY THERE ARE NO WARRANTIES EXPRESS OR IMPLIED OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OTHER THAN AS EXPRESSLY STATED HEREIN MPI SHALL NOT BE RESPONSIBLE FOR ANY INCIDENTAL INDIRECT PUNITIVE OR CONSEQUENTIAL DAMAGES WHETHER AS A RESULT OF BREACH OF WARRANT Y NEGLIGENCE STRICT LIABILITY IN TORT OR OTHERWISE Note Some jurisdictions do not allow a limitations on how long an implied warranty las
47. cator light provides diagnostic information for lockout recycling and patented cad cell status There is a manual reset button to exit the lockout mode and enter the idle mode See Fig 2 Operation is shown in Table 4 TROUBLESHOOTING AND MAINTENANCE IMPORTANT Due to the potential hazard of line voltage only a trained experienced service technician should preform the troubleshooting procedures This control contains no field serviceable parts Do not attempt to take it apart Replace entire control if operation is not as described To completely troubleshoot an oil burner installation check the burner and oil primary control for proper operation and condition The indicator light on the oil primary control provides lockout recycle and cad cell indications as follows 1 Flashing at 1 2 second on 1 2 second off system is locked out or in restricted mode 2 Flashing at 2 seconds on 2 seconds off control is in recycle mode 3 On cad cell is sensing flame 4 Off cad cell is not sensing flame Cad Cell Resistance Check For proper operation it is important that the cad cell resistance is below 1600 ohms During a normal call for heat once the control has entered the Run mode press and release the reset button See Table 3 for equivalent cad cell resistance and Fig 11 for an example of the cad cell resistance reading FCX INSTALLATION AND SERVICE MANUAL Cap 40 Preliminary Steps Check wiring connections and
48. consumer if necessary and any other materials necessary to perform the exchange 4 Replacement parts beyond the balance of the original warranty period REMEDY f within the applicable warranty period any product s or part s included in this warranty proves to be defective in material and or workmanship then MPI shall repair or replace at its option the defective product s or part s and return it to the consumer PROCEDURE FOR OBTAINING PERFORMANCE UNDER THIS WARRANTY In order to obtain performance under this warranty the original purchaser must promptly in no event later than thirty 30 days after discovery of the defect see to the return of the product s or part s in question accompanied by a properly filled out MPI warranty claim form Available from MPI by mail or phone Any claim made under this warranty must be accompanied by proof of original purchase date sales invoice or cancelled check showing the serial number as satisfactory evidence Any replacements are made subject to validation by MPI of in warranty coverage An item to be replaced must be made available in exchange for the replacement SOLE REMEDY The remedy and liability for any breach of warranty express or implied set forth herein is the sole and exclusive remedy and the limit of liability for any such breach EXCLUSIONS AND IMPLIED WARRANTIES This warranty does not extend to any defect due to the negligence of others failure to install op
49. ct to physical chemical or freeze damage The FCX is designed to be fueled with clean dry 2 grade or better home heating oil Use of substandard oil or other fuels will void this warranty Nozzle failure due to water or contaminants in fuel will not be covered This warranty does not cover physical chemical or freeze damage or use of antifreeze other than that approved by MPI Water of strong acidic or alkaline composition can damage the heat exchanger assembly and will void this warranty In addition the ingestion of chlorine or chlorine contaminating fumes or vapors fluorine or florine containing fumes or vapors fumes from animal confinement fumes from beauty parlors fumes from muriatic acid or other compounds used for cement cleaning fumes from mechanical parts cleaning fumes from dry cleaning establishments fumes from laundry fumes from manufacturing or industrial activity into the combustion air to the boiler can damage the heat exchanger assembly and will void this warranty of the heat exchanger assembly STANDARD PROVISIONS TERMS AND CONDITIONS THAT ARE COMMON TO ALL MPI INDIVIDUAL PRODUCT WARRANTIES These warranties are subject to the condition that the MPI product s must have been installed in accordance with manufacturer s instructions These warranties extend only to the first retail purchaser of the products and only to a product that has not been moved from its original installation site These warranties do no
50. d and adjusted by a qualified licensed if required oil service technician using properly calibrated combustion test equipment vacuum and pressure gages 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 or equipment tester control Adjust the burner as required to be below this maximum Check to determine that the CO2 rate is from 11 5 13 percent and that there is no CO production Adjust the burner as required to achieve this operating characteristic Measure the temperature of the flue gas exiting the unit to determine that it does not exceed 250 degrees F 120 C Combustion inspection can be carried out on the unit through the hole item N provided in the inspection port item 7 Be sure to replace the washer item M and the test point screw item 6 properly after inspection Factory Settings for the Burner Burner PIONEER 1 Oil pump pressure psig 165 170 Nozzle 0 50 80 AS Firing Head Adjustment 1 75 Air shutter Adjustment 6 8 For more detailed burner instructions refer to the Heatwise or the Beckett NX burner manual Fig 43 4 CHECKING THE SAFETY DEVICES At the time of start up check the safety and control devices as follows Thermostats Check to see th
51. d to four minutes and the ignition set in the intermittent mode for this cycle only The R7184 automatically reverts to its labeled interrupted and safety switch timing states The pump priming cycle can only be entered if there have been no lockout occurrences since the last successful heat call To reset the device so that the pump priming cycle can be entered press and hold the reset button until the light emitting diode LED flashes approximately 30 seconds Data Port Controls are designed to allow networking and upgrade modules to be added in the field by simply plugging them into the data port network See Fig 2 HONEYWELL CONTROL Disable Function Pressing and holding the reset button will disable all functions until the button is released The R7184 will restart at the beginning of the normal heat cycle on safety check Limited Reset Restricted Mode In order to limit the accumulation of unburned oil in the combustion area the control can only be reset three times The reset count returns to zero each time a call for heat is successfully completed To reset from restricted mode Press and hold the reset button for 30 seconds When the LED flashes twice the device has reset T T Jumper Select models have a pre installed T T jumper resistor To remove use side cutting pliers to cut the jumper See Fig 2 Lockout Mode The R7184 will enter the lockout mode when Flame is detected during valve on delay
52. e 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 F 110 C in the boiler This can occur if the water temperature control is near its maximum setting and or the three way valve is drawing its majority of water out of the secondary condenser This can be prevented if the water temperature control is turned to a lower temperature the three way valve is readjusted FCX INSTALLATION AND SERVICE MANUAL Cap 16 clockwise or the burner is rewired for a post purge A faulty water temperature control can also cause a shutdown After correcting any fault either thermostat must be manually reset by removing the screw cap on top and depressing the reset button Note Actuation of the reset button may not be physically visible Iftripped a button will have an audible click when trying to reset INLINE OILHEATER OR THERMOSTAT SHUTDOWN The heatwise Pioneer Burner is equipped with an inline oil heater this heats up and closes a thermostat for the burner to get power If the heater or the thermostat malfunction one complete unit it will not allow the burner to start If the fuel is extremely cold the inline heater may not be able to keep up and may momentarily shut off the burner
53. e boiler shell using the valve caps as the valve handle MAINTENANCE 1 CLEANING THE BOILER SHELL e Remove the screws B from the cast iron boiler shell cover C e Remove the flue outlet baffle D Note If vacuuming be careful not to damage insulator check for deterrieration and replace if needed Remove the combustion baffles E clean inspect and replace if deteriorated Clean the inner walls of the boiler shell remove any debrie that may have fallen to the bottom of the chamber Reassemble all the parts the way they were removed positioning the flue outlet D with its centering screw P towards the front of the boiler then positioning the boiler shell cover C arrow marker opposite the centering screw P Replace the screws B in the boiler shell cover B Fig 44 2 CLEANING THE CONDENSER e Remove the wing nut F from the condenser top cover G and remove the cover e Remove the condenser access plug 7 e Clean the condenser tubes H using a bottle brush or similar tool e Pour tap water through the condenser tubs to ensure combustion products can flow freely e Visually inspect vent house tee at condenser outlet for integrity e Replace the condenser access plug 7 and the top cover G making sure that the seal is properly positioned when replacing the cover e Make sure that the seal 1 on the cover and the access plug is in good condition e Inspect and cle
54. ed Canadian Underwriters Laboratories Inc Table 1 R7184 Models Valve on delay Burner motor off Alarm Typical Wiring Diagram Thermostat Model sec delay min Contacts Fig reference No Terminals T T R 184A None None None 3 4 5 Yes R 184B 15 None None 3 6 7 Yes R 184P 15 0 2 4 6 Optional 3 6 7 Yes R7184U Selectable O or 15 Selectable 0 or 0 2 4 6 Yes 3 6 7 Yes eSome select models may have a delay enable disable switch Standard timings Other timing may be available on select models Select models are provided with a T T jumper which can be disabled by cutting with a pair of side cutting pliers INSTALLATION When Installing this Product 1 Read these instructions carefully Failure to follow instructions can damage product or cause a hazardous condition 2 Check ratings given in these instructions and on product to make sure product is suitable for your application 3 Make sure installer is a trained experienced service technician 4 Use these instructions to check out product operation after installation WARNING Electrical Shock Hazard Can cause serious injury or death Disconnect power supply before beginning installation to prevent electrical shock or equipment damage Location 1 Mount on a 4 in by 4 in junction box directly on the main burner or inside the appliance cabinet In replacement applications mount in the same location as the old control S
55. ee Fig 1 Make sure the operating temperatures are within the ambient temperature range see Specifications section 2 Before mounting the control make line voltage connections as shown in Fig 2 through 7 Splice lines with solderless connectors Do not exceed load ratings shown on the device label 3 If necessary use the control as a template to mark and drill new mounting holes 4 Mount using No 6 screws obtained locally 31 he EO BURNER H Fig 1 Mounting R7184 on junction box WIRING 1 Make sure wiring complies with all local codes and ordinances 2 After mounting make low voltage connections to the screw terminals see Fig 2 through 7 3 Strip leads 3 8 in 10 mm and insert under terminal screw See Fig 1 4 Connect thermostat leads to T T Switch Settings Figure 8 and Table 2 provide the switch settings for the R7184U and R7184 for an oil fired forced air system www monitorproducts com HONEYWELL CONTROL CHECKOUT Start System INTERRUPTED CBOUMG L2 WARNING 9000 zemren FANRELAY CONTROL Fire Hazard Burner MOTOR Can cause 14 serious injury or death Make sure combustion chamber is free of oil and or oil vapor before starting system CAD CELL i Fig 2 Wiring terminals n 3 3 I REMOTE e Kach 1 Open hand valve in oil supply line ALAR A ALARM l IRCUIT D
56. en discovered perform an expansion tank check or if the pressure releif valve drips or pops occasionally 5 EXPANSION TANK PRE INFLATION PRESSURE CHECK 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 Check the pressure in the expansion tank and if necessary 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 e 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 psi where 2 41Ft in height 1 psi Adjust the filling pressure of the installation to a value greater than 3 psi 0 2 bar above the pre inflation pressure of the tank after totally bleeding any air from the installation Fig 42 Dilated water i Membrane Water inlet volume Pressure Max rses as Inflating vessel the air is valve volume compressed www monitorproducts com MAINTENANCE OPERATING FAULTS 6 COMBUSTION PRODUCT FLUE Examine the flue combustion air system for leaks and obstructions Leaks can generally be detected by the appearance of condensate stains on the outside of the pipes Replace any damaged seals if necessary The flue combu
57. er is factory set at 165 170 PSI This pressure is necessary to get the desired oil flow to maximize the nozzle output capacity for the FCX Do not exceed 175 PSI 6 3 There is a solenoid valve on the fuel pump to initiate a pre purge after the burner control starts airflow The Honeywell microprocessor control R 7184 P has a 15 second pre purge period Factory wiring does not allow for a post purge Follow specifications on the R 7184 P control to troubleshoot any control problems T FUEL 7 1 ASTM D396 No 1 or No 2 fuel must be used on the Pioneer burner A new oil tank is suggested with all installations If a new oil tank is not installed then the old oil tank should be less than ten years old and it should be checked thoroughly to ensure that sludge or other microbiological impurities are not present Oil tanks greater than ten years of age MUST be replaced before the installation is completed Vacuum readings greater than 5 Hg must be avoided Refer to the Suntec Installation Service Manual included with this document Note For the installation of the oil tank and oil lines refer to local codes Also some installations may require an Oil Safety Valve refer to local codes APPROXIMATE SETTINGS SEALED COMBUSTION Monitor Products GEMINOX FCX Boiler Condensing Boiler Burner Nozzle Model G P H Degree amp Make PSI Head Air Type Position Opening P 1 FV 0 50 80 AS Danfoss 175 1 75
58. erate or maintain the product s in accordance with the installation operation and maintenance instructions furnished with each new product unreasonable use accidents acts of god fire snow floods lightning alteration ordinary wear and tear or the use of unauthorized or nonstandard parts ALL IMPLIED WARRANTIES IF ANY ARISING UNDER LAW IN CONNECTION WITH THE SALES BY MPI OF ANY PRODUCT S ARE LIMITED IN EXTENT AND DURATION TO THE DURATION OF THIS WRITTEN WARRANTY THERE ARE NO WARRANTIES EXPRESS OR IMPLIED OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OTHER THAN AS EXPRESSLY STATED HEREIN MPI SHALL NOT BE RESPONSIBLE FOR ANY INCIDENTAL INDIRECT PUNIITIVE OR CON SEQUENTIAL DAMAGES WHETHER AS A RESULT OF BREACH OF WARRANTY NEGLIGENCE STRICT LIABILITY IN TORT OR OTHERWISE Note Some jurisdictions do not allow a limitations on how long an implied warranty lasts or b the exclusion or limitation of incidental indirect punitive or consequential damages so the above limitations or exclusions may not apply to you NO VARIATION OF TERMS the parties intend that this warranty be the exclusive and final expression of their agreement No person has the authority to orally in writing or in any other way vary the terms conditions or exclusions of this warranty or to make any express warranties other than those contained herein LEGAL RIGHTS This warranty gives you specific legal rights and you may also have ot
59. g ure 5 Failure to di this may introduce air into the system and could result in the loss of prime SOLENOID WIRING DISCONNECT POWER SUPPLY BEFORE WIRING TO PREVENT ELECTRICAL SHOCK OR EQUIPMENT DAM AGE Lead wire on these devices are long enough to reach the junction box on most burner installations Note check the burner manufacturer s installation sheet for correct sole noid wiring For all other applications wire solenoid in paral lel with burner motor See Figure 3 All electrical work should be done according to local and national codes Solenoid 115V 0 1A 60 Hz Figure 3 Burner Motor To Relay 115V 60 Hz GENERAL INFORMATION ALL SYSTEMS IMPORTANT INFORMATION Long or oversized inlet lines may require the pump to operate dry during initial bleeding FCX INSTALLATION AND SERVICE MANUAL period In such cases the priming may be assisted by inject ing fuel oil into the pump gearset Under lift conditions lines and fittings must be air tight To assure this Pipe Dope may be applied to both the used and unused inlet and both return fittings DO NOT USE TEFLON TAPE DO NOT USE COMPRESSION FITTINGS MOUNTING POSITION Model A Single Stage Fuel Unit may be mounted in any position Model B Two Stage Fuel Unit may be mounted in any position except upside down 1 8 ports pointed down VACUUM CHECK Avacuum Gage may be installed in either of the 1 4 inlet ports or in the 1 8 return po
60. g connections R7184 On hydronic systems Burner does not start e Disconnect line voltage power and open line switch jumper limit terminal and L1 of Check all wiring connections R 184 e Tighten any loose connections and recheck f burner does not start replace R7184 Condition Burner starts then locks out on safety with indicator light flashing at 1 2 second on 1 2 second off 7 Reset oil primary control by Indicator light stops Go to step 8 pushing in and releasing red reset flashing button Indicator light con tinues to flash at 1 2 second on 1 2 Verify that control is not in restricted mode If not in second off restricted mode replace R7184 8 Listen for spark after burner turns Ignition is off Spark ignitor could be defective Check for line voltage at on after a 2 second delay ignitor terminals If line voltage is present replace R7184 Ignition is on Go to step 9 Ignition is on but no oil is Wait for valve on delay to complete R7184B P and U being sprayed into the Check oil valve oil valve wiring pump and oil supply combustion chamber 9 Check indicator light after flame Indicator light is on until the Replace R7184 is established but before oil control locks out and starts primary control locks out flashing during lockout Indicator light stays off Go to step 10 10 Check cad cell sighting for view Burner locks out Go to step 11 of flame Burner keeps ru
61. her rights which vary from jurisdiction to jurisdiction Monitor Products Inc P O Box 3408 Princeton NJ 08543 732 329 0900 As part of its policy of continuous product improvement Monitor Products Inc reserves the right to make changes without notice PART NO 3000 COPYRIGHT 2004 MONITOR PRODUCTS INC FCX INSTALLATION AND SERVICE MANUAL Cap 48
62. ic 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 www monitorproducts com INSTALLATION 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 d
63. icator light after flame is established but before oil primary control locks out Indicator light is on until Replace R7184 the control locks out and starts flashing during lockout Indicator light stays off Go to step 9 Check cad cell sighting for view of flame Disconnect line voltage power and open line switch Unplug cad cell and clean cad cell face with soft cloth Check sighting for clear view of flame Place cad cell back in socket Reconnect line voltage power and close line switch Start burner Burner locks out Go to step 10 Burner keeps running Pi 35 System is Okay www monitorproducts com HONEYWELL CONTROL Procedure Status Corrective Actions 10 Check cad cell Disconnect line voltage power and open line switch e Remove existing cad cell and replace with new cad cell Disconnect all wires from thermostat terminals to be sure there is no call for heat Reconnect line voltage power and close line switch Expose new cad cell to bright light such as a flashlight Indicator light is on Indicator light is off Place control back on burner Go to step 6 Go to step 11 11 Check cad cell bracket assembly Disconnect line voltage power and open line switch e Remove cad cell wires from quickconnect connectors on the R7184 and leave control leadwires open Apply power to device Place jumper across cad cell
64. ilution 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 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 e 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 FCXINSTALLATION A
65. ing return C2 Underfloor heating circuit P2 2 circuit heating circulator VM2 2 circuit mixer valve Dc2 2 circuit heating output Rc2 2 circuit heating return Connection to a double e Ss Sd Heating output sensor heating circuit with a SEN a J C3 Domestic hot water production circuit domestic hot water lt gs C3 P3 Domestic hot water pump production system P3 B Domestic hot water production system Y Ss Domestic hot water sensor pi 11 www monitorproducts com INSTALLATION 6 1 SIRC PUMP CHARACTERISTICS Fig 39 Total Head in Feet HP range 1 25 1 12 1 6 Fluid temp 230 F Maximum 50 F Minimum Flow Range 10 46 GPM 20 25 30 35 40 45 50 Capacity in U S GPM 7 ELECTRICAL CONNECTIONS WARNING ELECTRICAL SHOCK HAZARD DISCONNECT THE POWER SUPPLY BEFORE ATTEMPTING ELECTRICAL INSTALLATION OF THE UNIT Electrical power and control connections are made to pigtail leads that exit through holes in the right rear of the unit facing the front of the unit The power connections must be made in a Listed junction Fig 40 LEGEND W White B Blue Gy Grey Br Brown wes mo Bk Black O Orange R Red Dk G Dark green Lt G Light green LEGEND L Phase Cx N Neutral M A On Off switch E H Summer Winter switch shell ground TSE Overheat safety cutout aquestat TRC Adjustable thermostat TSF Flue gas safety cutout thermost
66. ion 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 V OPERATING FAULTS 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 BURNER FAULT SHUT DOWN The burner may shut down for any of several reasons at which point the burner safety device light red on the control panel will be ON and the there will be a green fault indicator 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 restart after correcting any burner problem and the fuel supply is assured push the reset button on the burner The burner should restart after the preset time delay period expires OVERHEATING SAFETY THERMOSTAT SHUT DOWN 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 th
67. ir 6 Pump pressure 175 PSI YES Nozzle Danfoss 0 50 x 800 AS use a combination analyzer and a YES Does oil spray from smoke gun to the burner Clean and adjust the nozzle Do not adjust head Cad Cell and or A Cad Cell Bracket NO YES Re Disconnectnozzleline YES Does oil reach the Is the combustion good Cad Cell clean and from the gulis e pump positioned properly oil flow from the pump NO YES NO Confirm settings and Problem externalto readjustburner Check resistance on Cad Cell Replace solenoid valve the burner One flash 0 to 400 Ohms Two flashes 401 to 800 Ohms Three flashes 801 to 1600 Ohms Four flushes 1601 Ohms AMPI 27 www monitorproducts com HEAT WISE BURNER O ON O N 10 15 16 ITEM Blast Tube Flange Gasket Adjustable Flange Front piece Housing Rear piece Housing Fan Wheel 1 6 HP PSC Blower motor Shielding Plate Housing Outside Air Boot Air Regulation Plate Air Damper Air Regulation Adjustment screw Adjustment Screw Nozzle Line Ignition Cable Igniter Cover Plate Air Regulation 16 Cover Plate Nozzle Line 17 Scale Nozzle Line 17A Scale Air Regulation 18 FCX INSTALLATION AND SERVICE MANUAL Oil Pump Blast Tube 11764301 MPI PART 2526 Nozzle Line Pre Heater 11470605 MPI PART 2520 Cover Plate Nozzle Assembly 11887301 MPI PART 2548 PART 1
68. lation 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 inch mm 2256 39 37 1 3 15 80 9049 39
69. litres 5 1 5 2 10 3 10 7 Max heat exchanger power at Tm 80 C kW 35 35 60 62 Heat exchangeur surface dm 95 8 99 194 8 201 8 Heatlosses tank at 65 C W 58 77 97 136 BS performance with MZ 25 Max heat transfer kW Btu h 23 3 79500 on all tanks Minimum primary water flow m3 h 1 0 1 0 1 0 1 0 Primary heat exchanger pressure drop mbar 55 55 95 95 Reheating time to 60 C min 15 22 29 44 Continuous domestic water flow l min 11 2 11 2 11 2 11 2 BS DOMESTIC WATER HEATERS INSTALLATION INSTRUCTIONS MODELS BS 100 BS 150 BS200 BS 300 Volume drawn in 10 min at 40 C storage 65 C litres 173 241 313 476 Volume drawn in 1 hour at 40 C storage 65 C litres 731 798 870 1033 BS performance with MZ 20 40 Max heat transfer kW Btu h 35 0 119000 35 8 122000 Minimum primary water flow m3 h 1 5 1 5 1 5 1 5 Primary heat exchanger pressure drop mbar 120 130 200 210 Reheating time to 60 C min 10 15 19 28 Continuous domestic water flow I mIn 16 8 16 8 17 1 17 1 Volume drawn in 10 min at 40 C storage 65 C litres 229 261 313 476 Volume drawn in 1 hour at 40 C storage 65 C litres 1067 1098 1169 1332 BS performance with FCX Max heat transfer kW Btu h 22 3 22 3 22 3 22 3 Minimum primary water flow m3 h 1 0 1 0 1 0 1 0 Primary heat exchanger pressure drop mbar 55 55 95 95 Reheating time to 60 C min 15 23 30 45 Continuous domestic water flow I min 10 7 10 7 10 7 10 7 Volume drawn
70. lves and controls should be returned to an authorized service station or distributor of Heat Wise for determination of applicability of this LIMITED WARRANTY as to either repair or replacement where said service station or distributor is reasonably available in the customer s locality The manufacturers of burner components regularly publish and distribute listings showing the locations of their network of service stations Where such local service is NOT available for the burner components described above or other burner parts are involved these items should be returned freight prepaid to HEAT WISE Service Department 1528 Rocky Point Rd Middle Island NY 11953 2 Burners and or component s determined to be covered under this LIMITED WARRANTY by HEAT WISE shall be repaired or replaced at HEAT WISE s sole option 3 HEAT WISE is not responsible for any labor cost for the removal and replacement of said burner or burner components and equipment associated therewith 4 Aburner so repaired will then carry the LIMITED WARRANTY equal to the unexpired portion of the original burner LIMITED WARRANTY 5 If inspection by HEAT WISE does NOT disclose any defect covered by this LIMITED WARRANTY the burner or burner component s will be either repaired or replaced at the expense of the customer and HEAT WISE s regular charges will apply 6 If the original manufacturer of a burner component offers a warranty greater than either of our LIMITED WARRAN
71. n 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 FCXINSTALLATION AND SERVICE MANUAL IPI 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 e f 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 30 cm 12 in in M y mini 00cm mini 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 INSTALLATION Angled Balanced Flue Configuration Fig 16 1 ft minimum above max snow level Option Angled Horizontal Flue Kit Fig 17 To provide clearance around water connections a 1 2 meter concentric extension can be used Options Condensate Tee Concentric extensions 1 concentric vertical terminal
72. ncoils VM1 1 circuit mixer valve Dc1 1 circuit heating outlet Rc1 1 circuit heating return Rc1 Connection to a heating circuit with C1 C Boller a domestic hot water EE M Pressure gauge C1 Radiator circuit Baseboards Radiant Panels or Fancoils VM1 1 circuit mixer valve Dc1 1 circuit heating outlet Rc1 1 circuit heating return system Fig 36 C3 Domestic hot water preparation circuit P3 Domestic hot water pump C3 B Domestic hot water production system T Ss Domestic hot water sensor Connection to a double heating circuit C Boiler M Pressure gauge Low Temp III III C1 Radiator circuit VM1 f circuit mixer valve Dc1 15 circuit heating output Rc1 1 circuit heating return lev P2 dk E C2 Underfloor heating circuit d Wy C2 P2 2 circuit heating circulator VM2 254 circuit mixer valve Dc2 2 circuit heating output VM2 sd Rc2 2 circuit heating return Sd Heating output sensor Fig 37 Rc1 Note If the radiator circuit is high temperature baseboard then the connections at the boiler should be reversed with the baseboard loop using the DC2 circuit and circulator and the underfloor loop using the DC1 circuit which eliminates the need for VM2 since DC1 has one built in This applies to figs 37 and 38 C Bol oller M Pressure gauge C1 Radiator circuit VM1 1 circuit mixer valve Dc1 1 circuit heating output Rc1 1 circuit heat
73. nning System is okay a Disconnect line voltage power and open line switch b Unplug cad cell and clean cad cell face with soft cloth Check sighting for clear view of flame Place cad cell back in Socket c Reconnect line voltage power and close line switch d Start burner 11 Check cad cell Indicator light is on Place control back on burner Go to step 6 a Disconnect line voltage power Indicator light is off Go to step 12 and open line switch b Remove existing cad cell and replace with new cad cell c Disconnect all wires from thermostat terminals to be sure there is no call for heat d Reconnect line voltage power and close line switch e Expose new cad cell to bright light such as a flashlight 12 Check cad cell bracket assembly Indicator light is on Replace cad cell bracket assembly Refer to a Disconnect line voltage TRADELINE Catalog for bracket part numbers power and open line switch Indicator light is off Replace R7184 b Remove cad cell wires from quick connect connectors on the R7184 and leave control lead wires open c Apply power to the device d Place jumper across cad cell terminals after burner motor turns on a The EnviraCOM equipment can prevent the R7184 from turning on Aquastat equipment can send a Force Off message A miswired bus will prevent the R7184 from turning on also i 43 www monitorproducts com SUNTEC PUMP
74. 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 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 standa
75. ol 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 e 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 e Remove the front panel attachment screws P then pull the front panel J outward towards you atthe 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 FCX INSTALLATION AND SERVICE MANUAL INS TALLATION 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 e 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 e 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
76. ond off L Check that limit switches are 2 closed and contacts are clean Check for line voltage at the oil primary control Voltage should be 120 Vac Check indicator light with burner off no call for heat no Indicator light is on Cad cell or controller is defective sees external lighor connections are shorted Go to step 4 Go to step 5 Indicator light is off flame Shield cad cell from external light Indicator light turns off Indicator light stays on Eliminate external light source or permanently shielcad cell e Replace cad cell with new cad cell and recheck e If indicator light does not turn off remove cad cell leadwires from R7184 and recheck f indicator light turns off replace cad cell bracke assembly Refer to TRADELINE Catalog for bracket part numbers e f indicator light does not turn off replace controller FCX INSTALLATION AND SERVICE MANUAL Cap 42 HONEYWELL CONTROL Procedure Status Corrective Actions 5 On applications with valve on Indicator light is on f flame is present replace valve delay verify that oil valve is closed during the valve on delay period byopening view port and verifying that no flame is present during 15 second valve on delay 6 On warm air systems jumper Burner starts Trouble is in thermostat or limit circuit Check thermostat or thermostat terminals T to T on limit wirin
77. or the MPI FCX Boiler Nozzle line heater Okay D ee t N Turn power off and connect the power from wiring harness to LI black and limit red on the control NO Check capacitor if 140 the power back on the capacitor is does the motor start good replace motor YES Replace the Nozzle line heater FEE NO Does the igniter come on Check that all wiring connections are made and secure YES YES lt Igniter is okay 4 Does the igniter come NO pon Does the control give power to the igniter Replace electrodes YES Are there cracks inthe YES Does the control give electrodes power to the igniter NO NO YES Are the electordes YES Replace control gapped properly Replace igniter Regap orreplace Replace coupling YES Y YES I Does the igniter come on i NO s Burner electronically okay YES NO but needs adjustment Start the following points R eplace control NO Does the control give power Head 1 75 to the solenoid value A
78. ormed as a precaution to avoid any leaks that may have occurred during the installation process To check the vacuum follow guideline below 1 Attach a vacuum gauge to the oil line between the tank and the oil pump on the burner preferably near the oil filter 2 With the burner firing slowly shut off the oil line at the oil tank FIG 8 Air Leaks Check to ensure that fittings are not leaking and that there are no leaks at the stem of the firematic valve and Pump seals including the shaft and gasket areas 1 The return oil line ina two pipe system must always be in oil gll Tank 3 Watch the vacuum gauge and once it has reached 5 Hg of vacuum shut the burner off DO NOT exceed S Hg 4 Wait between five and ten minutes and check the pressure gauge again 5 If the gauge pressure has gone down then there is an air leak in the system that needs to be fixed before commissioning the burner See Fig 999 Dil Pump on Burner FCX INSTALLATION AND SERVICE MANUAL HEAT WISE BURNER Is there power from the boiler to the burner NO NO Check thatall wiring Doesthe Is the control NQ connections are motor start in lockout made and secure bt Ideas in Heating Wait 3 minutes and YES see if motor starts Troubleshooting Flow Chart i Problem External to the Burner Y Resetcontrol BIET oes the motor f
79. own in Fig 2 through 8 Splice lines with solderless connectors Do not exceed load ratings shown on the device label 3 If necessary use the control as a template to mark and drill new mounting holes 4 Mount the device using No 6 screws obtained locally WIRING WARNING Electrical Shock Hazard Can cause severe injury death or property damage Disconnect power supply before beginning wiring to prevent electrical shock or equipment damage More than one disconnect may be involved 1 Make sure wiring complies with all local codes and ordinances 2 Check to make sure that line voltage wiring is properly connected Refer to oil primary label and appliance wiring diagram for color codes 3 After mounting make low voltage connections to the screw terminals see Fig 2 through 10 4 Strip leads 3 8 in 10 mm and insert under terminal screw 5 Connect thermostat leads to T T or 1 2 3 if EnviraCOM is present if required by installation IGNITION TRANSFORMER d D vn wm ep um BURNER DCH 17688 Fig 1 Mounting R7184 on junction box Switch Settings Fig 9 and Table 2 provide the switch settings for the R7184P and R7184U CHECKOUT Start System WARNING Fire or Explosion Hazard Can cause severe injury death or property damage Make sure the combustion chamber is free of oil and or oil vapor before starting system FCX INSTALLATION AND SERVICE MANUAL MPI 38 1 Open
80. power supply Make sure power is on to controls Make sure limit control is closed Check contacts between ignitor and the electrodes Check the oil pump pressure Check the piping to the oil tank Jo Q P N Check the oil nozzle oil supply and oil filter Check Oil Primary Control If the trouble is not in the burner or ignition hardware check the oil primary control by using the following equipment 1 Screwdriver 2 Voltmeter 0 to 150 Vac range 3 Insulated jumper wire with both ends stripped WARNING Electrical Shock Hazard Can cause severe injury death or property damage Troubleshoot with the system powered Be careful to observe all precautions to prevent electrical shock or equipment damage Refer to Table 4 for further troubleshooting information COOLING CONTROL BURNER MOTOR REMOTE CAD 4 ALARM A ALARM CELL LEGEND e SCREW TERMINAL gt gt 1 4 IN QUICK CONNECT TERMINAL SOLDERLESSWIRE CONNECTOR AN POWER SUPPLY PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED OPTIONAL FEATURE ON SELECT MODELS REFER TO DEVICE LABEL FOR WIRE COLOR CODE AN ENVIRACOM TERMINAL 3 IS ALSO THE FIRST THERMOSTAT TERMINAL Fig 9 Typical wiring diagram for24 Vac thermostat and R7184 for valve on delay burner motor off oil burner system HONEYWELL CONTROL Table 2 Switch Settings and Delays
81. r complete valve on delay period and then apply power to the valve 4 Control enters Trial for Ignition period a Monitors burner for flame b When flame is not detected 1 Enters lockout mode after lockout time of 15 30 or 45 seconds 2 Shuts off valve ignitor and burner motor 3 Flashes indicator light at 1 Hz 1 2 second on 1 2 second off 4 Depress reset button to return to power up sequence c When flame is detected Carry Over period begins 5 Control enters Ignition Carry Over period continues to spark for 10 to 30 seconds a Turns on indicator light b If flame is lost and lockout time has not expired R7184 returns to Trial for Ignition period c If flame is lost and lockout time has expired R7184 enters Recycle Mode 6 Carry Over time expires ignitor turns off 7 Enters Run Mode a Flame is monitored until call for heat ends or flame is lost If flame is lost 1 Control enters Recycle Mode 2 Recycle time starts 60 seconds 3 Burner and valve are turned off 4 Indicator light flashes at 1 4 Hz 2 seconds on 2 seconds off 5 Returns to Idle mode at end of Recycle mode Call for heat is satisfied 1 R7184A U if burner motor off delay is disabled a Burner motor and oil valve shut off b Indicator light turns off 2 R7184B P U if burner motor off delay is enabled a Oil valve shuts off b Burner motor runs for selected burner motor off delay c Burner motor turns off d Device returns
82. r of recycle trials for each call for heat to a maximum of three trials If the flame is lost three times and does not successfully satisfy a call for heat the R7184 locks out Pump Priming Cycle To facilitate purging air from the oil lines and filters the R7184 can be placed in a purge routine by pressing and releasing the reset button during the safety check delayed valve on ignition or carry over periods The lockout timing will be extended to 4 minutes and the ignition set in the intermittent mode for this cycle only The R7184 automatically reverts to its labeled interrupted and safety switch timing states The pump priming cycle can only be entered if there have been no lockout occurrences since the last successful heat call To reset the device so that the pump priming cycle can be entered press and hold the reset button for 30 seconds until the LED flashes twice Disable Function Pressing and holding the reset button will disable all functions until the button is released The R7184 will restart at the beginning of the normal heat cycle on safety check Limited Reset Restricted Mode In order to limit the accumulation of unburned oil in the combustion area the control can only be reset three times The reset count returns to zero each time a call for heat is successfully completed To reset from restricted mode Press and hold the reset button for 30 seconds When the LED flashes twice the device has reset HONEYW
83. r pressure exceeds 60 PSI 4 bars make provision for a pressure reducer Always set the boiler temperature at least 10 C higher than the desired storage temperature in the domestic hot water tank Leave sufficient space above the tank to allow access to the inspection trap The trap seal must be replaced with every inspection Hydraulic connections 1 Primary inlet 2 Domestic hot water supply outlet 3 Recycling 4 Primary outlet 5 Domestic hot water supply inlet m FCX INSTALLATION AND SERVICE MANUAL Cap 46 The insulation 6 laid on the top of the tank in the packing must be fitted to the shell under the tank before the tank is installed Electrical connections for BS DHW Tank 24 Volts 60 Hz interne internal innen n externe external auBen 3 N HORMEL EEF Oey 7 LEER 0 Ill TECHNICAL DATAS MODELS BS100 BS 150 BS200 BS 300 Capacity litres 100 150 200 300 Heigth mm 700 925 1150 1600 Diameter mm 600 600 600 600 Primary connection pouces Ya Ya Ya YA Domestic and recycled connection pouces Ya Ya Ya Boiler heat exchanger max operating pressure psi 90 90 90 90 Max domestic hot water pressure psi 100 100 100 100 Electrical connections 24 volts 60Hz on all tanks Domestic hot water thermostat C 20 80 20a80 20480 20a 80 Thermostat differential C 6 6 6 6 Inspection trap mm 100 100 100 100 heat exchanger pipe mm 25x1 25x1 25x1 25x1 Primary capacity
84. rd option flue piping components and packages with which to create the flue system are available 0 98 m Straight Horizontal Flue Kit Fig 5 Sy 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 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 Reference No MPI Part 2209 V72 28414 MPI 3 m angled horizontal balanced flue straight Fig 7 Ew Ke Km Reference only PP PVC Concentric Vertical Terminal For Flat or Sloping Roof Fig ig 8 Z 1 7 a 2 Reference Color Length I D O D MPIPart2206 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 IA Fig 9 Reference Length 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 4
85. rior to operating the relief valve to assure that hot water discharged from the relief valve will not contact people or damage property VII WARNING Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water heater used for space heating Hotter water increases the risk of scald injury Before changing temperature setting see the instruction manual HOT WATER CAN PRODUCE 75 DEGREE BURNS IN 6 SECONDS AT 140 F 60 C IN 30 SECONDS AT 130 F 54 C e Maximum permissible potable water outlet temperature for this appliance is 180 F e When system requires water for space heating at temperatures higher than required for other uses a means such as a mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential See piping diagram below d way mb ng valve Domestic hof A Domestic cold water from i A water from unit EN household f N J e supply Wami water to poini of use www monitorproducts com WARRANTIES MONITOR PRODUCTS INC MPI LIMITED WARRANTIES BS INDIRECT WATER STORAGE TANK First year MPI warrants each BS tank sold by it to be free from defects in material and workmanship for a period of 1 year from date of original purchase with an additional period of up to 3 months if unit was not installed at the time of purchase First through tenth year MPI warrants that the s
86. rmation Procedure Status Corrective Actions 1 Check that limit switches are closed and contacts are clean 2 Check for line voltage power at the oil primary control Voltage should be 120 Vac Check indicator light with burner off no call for heat no Indicator light stays on Cad cell or controller is defective sees external ligh or connections are shorted Go to step 4 flame Shield cad cell from external light Indicator light turns off Indicator light stays on Eliminate external light source or permanently shield cad cell Replace cad cell with new cad cell and recheck If indicator light does not turn off remove cad ce leadwires from R7184 and recheck If indicator light turns off replace cad cell bracke assembly Refer to TRADELINE Catalog for bracket part numbers e f indicator light does not turn off replace controller On warm air systems jumper thermostat terminals T to T on R7184 On hydronic systems jumper limit terminal and L1 of R7184 Burner starts Trouble in thermostat or limit circuit Check thermostat or limit wiring connections Disconnect line voltage power and open line switch Check all wiring connections Tighten any loose connections and recheck e f burner does not start replace R7184 Burner does not start Condition Burner starts then locks out on safety with indicator light flashing at 1 2 second on 1 2 sec
87. rs e If indicator light does not turn off replace controller 5 On warm air systems jumper thermostat T to T terminals on R7184 On hydronic systems jumper Limit terminal and L1 of R7184 IMPORTANT First remove one thermostat lead Burner starts Trouble is in thermostat or limit circuit Check thermostat or limit wiring connections Burner does not start Disconnect line voltage power and open line switch Check all wiring connections e Tighten any loose connections and recheck e f burner does not start replace R7184 Condition Burner starts then locks out on safety with i ndicator light flashing at 1 Hz rate 1 2 second on 1 2 second off 6 Reset oil primary control by pushing in and releasing red reset button Indicator light stops flashing Go to step 7 Indicator light continues to flash at 1 Hz ratea Verify that control is not in restricted mode see footnote a If not in restricted mode replace R7184 Listen for spark after burner turns on after a 2 second delay Ignition is off Spark ignitor could be defective Check for line voltage at ignitor terminals If line voltage is present replace R7184 Ignition is on Go to step 8 Ignition is on but no oil is being sprayed into the combustion chamber Wait for Valve On Delay to complete R7184B P and U Check oil valve oil valve wiring pump and oil supply Check ind
88. rt on single pipe instal lations whichever is most convenient The Model A Pump should be used where the vacuum does not exceed 6 hg single pipe and 12 hg two pipe The Model B should be used where vacuum is the total of all exceed 17 hg Reminder running vacuum is the total of all pressure drops in the system form tank to inlet of pump PRESSURE CHECK Ifa pressure check is made use GAGE PORT OR NOZZLE PORT DO NOT USE EASY FLOW BLEED VALVE PORT FOR THE 7000 SERIES The Easy Flow Bleed Valve Port contains pressure higher than operat ing pressure Setting pump pressure with gage in the Easy Flow Bleed Valve Port results in WRONG operating pres sure The 2000 series and 7400 series are exceptions See Figure 2 CUTOFF PRESSURE Average cutoff pressure for A and B fuel units is 80 psig To check cutoff pressure install pres sure gage in nozzle port Run burner for short period of time Shut burner off Gage shows cutoff pressure Pressurized or gravity feed installations must not exceed 10 PSI on inlet line or return line at the pump A Pressure greater than 10 PSI may cause damage to the shaft seal A SUNTEC PUMP ONE PIPE SYSTEM MODEL A IDENTIFICATION EXAMPLE PUMP Model Strainer Series Air vent Ce L H R USAGE number Fill pipe IDETIFICATION N A1VA 7112 Fuel unit Aux filter Rotation amp Nozzle Location Shut off
89. s INSTALLATION PPtIIPVC Condensate Tee Joint joint fitting I Fig 28 O D 4 92 I D SN Reference Length 2255 10 Length does not include drain spicket Useful length after assy 2 PPtIIPVC Parallel Concentric Adapter Male Top joint fitting Fig 29 c Reference No Length I D O D 2253 3 5 9 15 4 92 PPtI PVC Parallel Concentric Adapter Female Bottom joint fitting Fig 30 Reference No Length I D O D 2254 T 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 MPI 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 amp 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 concentr
90. s on the burner housing at either side of the flame tube Remove the flame tube to expose the nozzle assembly Now using 8 4 mm allen key loosen the retention head screw and separate the retention head electrode assembly from the nozzle line Remember to disconnect the rajah connector from the electrode assembly Using two 5 8 wrenches remove the nozzle from the nozzle line Install a new nozzle FCX INSTALLATION AND SERVICE MANUAL HEAT WISE BURNER 2 WIRING THE BURNER 2 1 Follow the wiring diagram shown in Fig 2 All the wiring should conform to the National Electric Code NEC or the legally authorized code governing your locality When wiring be sure that the electric power take off is connected to a permanently live circuit The power supply must have a 15 amp circuit breaker or fuse with a service switch located not more than 3 feet from the burner FIG 2 WIRING DIAGRAM WITH NOZZLE LINE HEATER IN SERIES 3 HEAD ADJUSTMENT 3 1 Head adjustment is set at the factory Graduations are numbered from 1 to 22 on the head adjustment dial See Fig 3 By turning the head adjustment screw clockwise the burner head will move inside the blast tube AWAY from the end cone The head adjustment dial is set at 1 75 at the factory which is 1 mm away from the tip of the end cone see Fig 4 The head position needs to remain at the set distance to ensure proper combustion 4 AIR SHUTTER ADJUSTMENT FIG 4
91. stion 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 excess water in the condensate trap when cleaning is completed 7 CHANGING A THERMOSTAT OR THE THERMOMETER Replacement of the thermostats or the thermometer requires removal of the bulb from its location and the control from the control box The bulb for the Boiler Temperature Thermometer is located on the first circuit heating output 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 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 remove the bulb from the pocket 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 replacing the bulb properly into the pocket as far as possible The bulb for the Combustion Product Overheating Thermostat is located in a well provided in the condenser access plug inspection port Remove the combustion test point plug and washer from the inspect
92. t apply to commercial applications In addition to each product warranty listed MPI warranties do not cover 1 Components that are part of the heating system but were not furnished by MPI as part of the heating system 2 The workmanship of any installer of MPI s product s In addition this warranty does not assume any liability of any nature for unsatisfactory performance caused by improper installation 3 Any costs for labor for removal and reinstallation of the alleged defective part the cost of shipping or transportation to MPI and back to the consumer if necessary and any other materials necessary to perform the exchange 4 Replacement parts beyond the balance of the original warranty period REMEDY If within the applicable warranty period any pro duct s or part s included in this warranty proves to be defective in material and or workmanship then MPI shall repair or replace at its option the defective product s or part s and return it to the consumer PROCEDURE FOR OBTAINING PERFORMANCE UNDER THIS WARRANT Y In order to obtain performance under this warranty the original purchaser must promptly in no event later than thirty 30 days after discovery of the defect see to the return of the product s or part s in question accompanied by a properly filled out MPI warranty claim form Available from MPI by mail or phone Any claim made under this warranty must be accompanied by proof of original purchase d
93. tage safety rated interrupted ignition oil primary control for residential oil fired burners used in boilers forced air furnaces and water heaters The R7184A B P U used with a cad cell flame sensor operates an oil burner and optional oil valve The primary controls fuel oil senses flame controls ignition spark and notifies a remote alarm circuit when in lockout The R7184 can be used with both hydronic and forced air systems When used with hydronic systems line voltage switching Aquastat Controllers normally provide for the starting and stopping of the combustion sequences With forced air systems both mechanical and electronic low voltage thermostats control the starting and stopping of the combustion process Some hydronic and forced air systems now require a delayed valve on and burner motor off delay The R7184 operates an oil valve that prevents the flow of oil when the burner motor is running prior to combustion delayed valve on and when the burner motor is running after combustion burner motor off delay The R7184 models are intended for use only on oil burning appliances which do not require prepurge and post purge as a safety related function as defined in UL 296 The valve on delay and burner motor off delay in this control are intended only to help establish draft and reduce oil after drip related problems FCXINSTALLATION AND SERVICE MANUAL Cap 30 FEATURES Limited Recycle This feature limits the numbe
94. tainless steeltank and heat exchanger is free from defects in material and workmanship for 10 years from date of purchase Items not covered The BS tank is designed to be filled with clean potable water Corrosion caused by chemically aggressive water voids this warranty Homeowners obligation The homeowner must show credible written evidence of anode rod inspection and replacement when necessary according to the schedule found in the installation instructions STANDARD PROVISIONS TERMS AND CONDITIONS THAT ARE COMMON TOALL MPI INDIVIDUAL PRODUCT WARRANTIES These warranties are subject to the condition that the MPI product s must have been installed in accordance with manufacturer s instructions These warranties extend only to the first retail purchaser of the products and only to a product that has not been moved from its original installation site These warranties do not apply to commercial applications In addition to each product warranty listed MPI warranties do not cover 1 Components that are part of the heating system but were not furnished by MPI as part of the heating system 2 The workmanship of any installer of MPI s product s In addition this warranty does not assume any liability of any nature for unsatisfactory performance caused by improper installation 3 Any costs for labor for removal and reinstallation of the alleged defective part the cost of shipping or transportation to MPI and back to the
95. to Idle mode Reset button pushed two 1 R7184 enters Restricted mode times without device 2 Indicator light flashes at 1Hz 1 2 second on 1 2 second off completing a call for heat 3 Reset device by pressing and holding reset button for a minimum of 30 seconds Procedure Table 5 Troubleshooting Information Status Corrective actions Condition Burner does not start with a call for heat 1 Check that limit switches are closed and contacts are clean 2 Check for line voltage power at the oil primary control Voltage should be 120 Vac Indicator light is on Cad cell or controller is defective sees external light 3 Check indicator light with burner off no call or connections are shorted Go to step 4 for heat no flame Indicator light is off Go to step 5 FCX INSTALLATION AND SERVICE MANUAL api 34 HONEYWELL CONTROL Procedure Status Corrective Actions 4 Shield cad cell from external light On warm air systems jumper thermostat T to T terminals on R7184 On hydronic systems jumper Limit terminal and L1 of R7184 IMPORTANT First remove one thermostat lead Indicator light turns off Eliminate external light source or permanently shield cad cell Indicator light stays on Replace cad cell with new cad cell and recheck e If indicator light does not turn off remove cad cell leadwires from R7184 and recheck e f indica
96. tor Wieland 7 pis INSTALLATION START UP AND OPERATION UPPER LEFT REAR CORNER OF UNIT Facing rear of unit Fig 41 2 d y 1 f i V J l 3 Sg li i x 1 Junction box 2 Main Power Pigtail Leads 3 Unit Upper Back Panel 4 Control circuit Pigtail Leads 111 START UP AND OPERATION 1 PRE START FINAL SYSTEM CHECK Before starting normal operation of the boiler and heating system perform the following final installation 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 Recheck the power and control circuit connections THEN replace all cabinet access panels Energize the electrical power circuit to the unit 2 START UP AND OPERATION After completing the pre start final system checks the system can be started and run through start up checks and adjustments as required 1 Start Stop Switch 2 Summer Winter Switch Circulator control inside the boiler There are three 7 8 holes in the right rear of the unit Mount a Listed 2 x 4 inch HandiBox type junction box verticall
97. tor light turns off replace cad cell bracket assembly Refer to TRADELINE Catalog for bracket part numbers f indicator light does not turn off replace controller Burner starts Trouble in thermostat or limit circuit Check thermostat or limit wiring connections Burner does not start Disconnect line voltage power and open line switch Check all wiring connections e Tighten any loose connections and recheck e f burner does not start replace R7184 Condition Burner starts then locks out on safety with indicator light flashing at 1 Hz rate 1 2 second on 1 2 second off 1 Check that limit switches are closed and contacts are clean 2 Check for line voltage power at oil primary control Voltage should 120 Vac Check indicator light with burner no call for heat no flame Indicator light is on Cad cell or controller is defective sees external light or connections are shorted Go to step 4 Indicator light is off Go to step 5 Shield cad cell from external light Indicator light turns off Eliminate external light source or permanently shield cad cell Indicator light stays on Replace cad cell with new cad cell and recheck e If indicator light does not turn off remove cad cell leadwires from R7184 and recheck e If indicator light turns off replace cad cell bracket assembly Refer to TRADELINE catalog for bracket part numbe
98. ts or b the exclusion or limitation of incidental indirect punitive or consequential damages so the above limitations or exclusions may not apply to you NO VARIATION OF TERMS the parties intend that this warranty be the exclusive and final expression of their agreement No person has the authority to orally in writing or in any other way vary the terms conditions or exclusions of this warranty or to make any express warranties other than those contained herein LEGAL RIGHTS This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction As part of its policy of continuous product improvement Monitor Products Inc reserves the right to make changes without notice PART NO 3000 COPYRIGHT 2007 MONITOR PRODUCTS INC PI 17 www monitorproducts com VII PARTS BREAKDOWN FCX FCX INSTALLATION AND SERVICE MANUAL Pi 18 PARTS BREAKDOWN MPIPARTS DESCRIPTION 1 2300 FRONT COVER EQUIPPED 2 2301 INSULATION FRONT COVER 3 2302 RIGHT HAND SIDE COVER EQUIPPED 4 2303 INSULATION RIGHT HAND SIDE 5 2367 FOLDED NECK 6 2368 INSULATION FOR BOILER SHELL 7 2304 PAINTED CONNECTING FLANGE 8 2305 PAINTED BACK COVER 9 2362 SWIRLERS 10 2369 COMBUSTION CHAMBER 11 2366 MINERAL WOOL 90 KG DISK DIAMETER 262X20 12 2370 FASTENING ANGLE 13 2371
99. ve bottom of tank L H R S D 3 8 an ue 9D 3 8 OD Tubing 1 2 OD Tubing Tubing Tubing Air vent Fuel unit Fig 5 3 GPM 3 GPM 3 GPM 7 GPM 3 GPM 7 GPM TM 86 100 84 71 100 100 Fill pipe Aux filter 0 80 100 78 66 100 100 1 5 100 T3 62 100 100 2 7 100 68 57 100 100 3 64 100 63 53 100 100 4 59 100 5f 48 100 100 5 54 100 52 44 100 100 D 49 100 47 39 100 100 T 43 100 42 35 100 100 8 3f 100 36 31 100 100 9 os 100 31 27 100 100 10 26 100 26 22 100 St 11 21 85 21 18 83 ZU Always terminate return line as shown in figure 5 Line length ia 63 j 62 52 includes vertical and horizontal lengths T i 41 35 B TWO STAGE TWO PIPE MAX LINE LENGTH H R Lift 1725 RPM 3450 RPM H 3 8 OD 1 2 OD 3 8 OD 1 2 OD f Tubing Tubing Tubing Tubing Fig 5 3 7 3 7 3 7 3 7 GPM GPM GPM GPM GPM GPM GPM GPM 100 91 100 100 93 80 100 100 cee 2 100 82 100 100 85 73 100 100 Rockford Illinois 61125 7010 A A CAES B Es 6 80 67 100 100 69 DO 100 100 815 226 3700 e 70 59 100 400 60 52 100 100 10 61 51 100 100 52 45 100 100 working harder to serve you even better 12 51 43 100 100 44 39 100 100 14 41 35 100 100 30 3T
100. y over the lower left hole facing the rear of the unit in such manner that the lower right hole is open When installing the junction box center the box vertically over the hole by using the center knockout in the box Install a 1 2 inch trade size cable connector or insulating bushing through the hole in the unit and through the knockout in the box Secure the box with screws as required Route the factory supplied main power pigtail leads through the connector into the junction box from inside the unit and secure the connector clamp on the wires Install a second cable or conduit connector in another knockout in the box for the power wiring system as required Connect the power wires and grounding 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 lower right hole from inside the unit Connect the room thermostat wires to the con circuit pigtail leads using a suitable Class 2 wiring connection method 8 FUEL OIL SUPPLY CONNECTIONS The buner supplied with the unit is connected to the boiler Lines are terminated with 3 8 inch reverse flare fittings for connection of the supply from the fuel oil tank When connecting the line a 10 micron spinon type oil filter must be installed in the oil supply line to minimize burner contamination 3 Boiler Temperature Control Thermostat Boiler Temperature adjusted between 140 176 deg F 6

Monitor FCX & DHW Owner and Service

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Monitor FCX &amp; DHW Owner and Service

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Monitor FCX & DHW Owner and Service