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Burnham FM01FD00B Boiler User Manual

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2. assesses nesses 68 Maintenance of Low Water Cutoff Devices 69 Checking Burner amp Controls 1 n nass tnn nnn 70 70 General Maintenance 70 Attention to Boiler While Not Operation 70 Recommended Periodic Testing necessest nennen nenne nnn nnne nnne 71 SECTION VII BURNER SPECIFICATIONS Beckett Burners Tables and 73 Power Flame Burners Tables XIVa XIVb 74 SECTION VIII REPAIR PARTS Regional Office Directory eene nennen nanus 76 Cast Iron Section 76 Common Bare Boiler 78 Fr
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4. tee eel ll f 111 Panels Cartons cen 10183811 Jos 10188832 Jos 8 10188841 003 15 10183815 ti Jos 6 10188816 003 17 10183817 10188481 Continued KNOCKDOWN BOILER EQUIPMENT CHECK LIST oe Carton 5 Designation Part elles Component Description on Bar Number 8 8 Code Label 212 Parts Cartons Continued 644 sso 10183905 0 806 47 queso 10183908 Continued 10888091 Pere meses T T T 4 Cartons Required 4 2 10183912 per Boiler 9e 10414 01888441 1 264 101839151 40418 10183971 9e 10183918 moo 1 10184002 sss 101
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6. E e s era vn vn er Se es ES 5 5 01 N 80 5 23 0 3213 2694 2343 88 4 858 J 318 3 9865 4 10470 1 Suffix N indicates natural gas fired suffix P indicates LP LP gas fired O indicates oil fired C indicates combination natural gas oil fired D indicates combination LP gas oil fired 2 I B R net ratings shown are based on 1 15 piping and pickup factor for water Consult manufacturer for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc 3 The IZB R burner capacity in GPH is based on oil having a heat value of 140 000 BTU per gallon 4 Boiler ratings are based on 13 2 CO oil and 10 2 CO natural gas and 10 water column pressure at boiler flue outlet Ratings shown above apply at altitudes up to 1000 feet on oil and 2000 feet on gas For altitudes above those indicated the ratings should be reduced at the rate of 496 for each 1000 feet above sea level Safety Relief Valve Set Pressure Standard 50 PSI Optional 30 PSI 80 PSI 12 SECTION 1 GENERAL INFORMATION Continued A INSPECT SHIPMENT carefully for any signs of damage 1 ALL EQUIPMENT is carefully manufactured inspected and packed Our responsibili
7. S Figure 55 MPC Cast Iron Section Assembly S M ow 76 LO LOZLOL VV V V V V V V V V V p Y Ajquiessy Buds uoisuej 09709808 ONES MEE Sie UT UE NEN WE uu c x xw ww X INN LL X 8 S l 80909808 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 SSN 1214 8 9 01 55709808 amm DE 8 9 8 70 0 IE peie d INN 8 2 8 9 6 58019808 8 Y 67 76 11 8 9 48 22019808 8 Y v TaZ X 8 9 738 10 96 101 v v O1 2 L Sv X 8 9 708 LO SSZLOL v v v 61 v X 8 9 728 LO vSZL0L v v v v 8 6 88 LO ESZLOL v v 81 v L v2 X LL 8 6 V8 8 e xserc 0 669101 4 9 Gk vL et cb OF 6 8 4 9 1 auos nood 61 91 X BIJ 8 2 10688 00 de EF E X qu c Bod 8 7009904 Zp 9 k O 6 8 9 G p peuiuoe N ejddiN ds 1520 6 200990 Zt Ot SL 2 OL 6 8 21 9 G p ejddiN ds 15 9 10 999001 10044 d OdN 10 99001 9L SL vl L tL OL 6 8 21 9 S p 2 uonoes 5 O OdN Z 10 89900 1 uonoes H OdN 8 2 9L S
8. 1 D1 2 L EX91 8 v 9916 Mal0S LJAN 19945 81009808 80 807 96 96 96 96 96 vc vo vo vo vo Cl 01 pear gy 64 2 1 88 6 10 19400 8 8 9 9 9 9 9 v v v v v c 9 uoddng 4 Joyner 2 10 89400 7 6 6 6 6 6 uoddng ejuozuod eurej4 jexoep 81 21 9 vL EL cL OF 60 80 70 90 60 O ON ON uonduoseq suonoes AIEINASSV 3IAVH3 NOILO3S 8 LNOYS 51 HIVd3H 83 SECTION REAR ADJACENT CENTER SECTION 84 Figure 58 MPC Rear Section Frame Rail Assembly 10 65200 z z z z z z z z z z z z z cz peiureg jeuueu epis jeonieA eurej4 PAF 61 09909804 2 2 2 2 2 2 2 2 2 2 2 2 4 2 c uleld INN 11 8 8 21 80900808 v VY Y t Y SSN 1814 8 6 IL 18809802 2 2 Z 2 Z Z 2 2 2 Z Z 4 48 c og 67 2 X 1 8 9 01 zZz zZz zZz 5 zZz zZz z jexoeJg JOY 6 86709808 v VY Y t Y 9915 INN 4 payeues 91 8 2 8 81909808 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 SSN 1614 8 8 Z 20 4660 Z 2 Z 2 2 4 2 Z 2 4 4 2 2 2 jeoeds 61 2 2 1 dl 91 Z X QO 91 1 9 60 600 0 Z l
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10. Q IO3INVIN 5 102 10 286101 65709108 85709108 10 68101 69709108 00709108 10 98101 216709108 95909108 10 886101 69709108 60209108 10 866101 81209108 ON Hed 81 2 91 91 YL cL OF 60 80 ZO 90 60 70 01 OS X LAN 7e 069211 gg 190171661 vg 043002 1H X LAN 14821 aM SLOZV90071 M07 YBIH 5 OE X LAN 2822 lOM uorsjeuuu ge 6811990071 ve 041u02 944 jur YBIH 02 uomne nsu X LAN 1 86 21 JOM uorseuuu 782 LL390071 ve YBIH 01 OON AL eqoJd M OZ L LIN d 08 19 8 OOMT VIE jO 1nO eqoud uonduoseq STOYLNOD TVNOILdO NOWINOD SLYVd HIVd3H ON 103 Figure Number Equipment Check List Figure 1a 2 Section Genera
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12. 4 91 4 8 se epis uo 1exoef spee ssousey AjeordA sesodind 40 SIU uwous sseuJeu LHOTS OL SH3 0O 553204 ONINY312 204 35 503 26 N340 INWE INUNA 10 uoisueuuip 14 Aew jaued saung e mea EEA lal Sg1 Assy ezis eoue ea 9 E E 5 uonejejsu yeyoog vwa a 9114 59 94 Jeuing uoneuloJu jeuoisueuuiq NOILVINHOJNI IVH3N39 NOILO3S 11 TABLE Il RATINGS DATA Model Boilers 8 D ES Q Intertek Combustion Efficiency R Rating B Sq Ft Water Content Boiler Weight Boiler Model Boiler Horsepower Gross Output MBH Net Heating Surface Net Furnace Volume Pressure in Firebox Inches Wtr Column Vent Flue Outlet m ree sse ur ee ime m 8 36 1 10 2 1428 1438 1209 1051 MPC9 41 7 11 8 1652 1660 1395 1213 859 1764 167 045 137 po mor o ro meo mo w sa s m ro ur vos
13. VENT DAMPER ASSEMBLY SUPPLY MANIFOLD Figure 46 Install Flue Outlet Damper Assembly U Install Optional Split Jacket Panels for Burner Swing Door BSD Cover if applicable 1 2 Locate hanger bracket for BSD cover secure to jacket front panel with three 3 48 x 1 2 hex head SMS as shown in Figure 47 3 Install left side BSD cover panel with offset bend as shown in Figure 47 Engage hooks on outer edge of panel through slotted openings on jacket front panel installed on boiler At the same time engage top flange of left cover panel behind hanger bracket see Figure 47 Detail Pull down on left cover panel to lock hooks in slots and top flange behind hanger bracket JACKET FRONT PANEL B S D COVER PANEL HANGER BRACKET 3 8 X 1 2 LG HEX 4 SLOTTED HOLES 4 LOCKING LOGO PLATE of HOOKS Open carton and remove contents LEFT COVER PANEL DETAIL 6 8 X 1 2 LG HEX HEAD SMS JACKET FRONT Install right side BSD cover panel using the same procedure used on left cover panel Before locking panel in place make sure right cover panel overlaps offset flange of left cover panel Secure panels together at seam using six 6 8 x 1 2 1g hex head SMS one 1 screw on top and five 5 screws on the face as shown in Figure 47 Locate Logo Plate shipped in Instruction Envelope Peel paper off adhesive strips and install by inserti
14. flow analysis should be performed to determine the flow through the boiler when the minimum and smallest and maximum number of zones are activated Sufficient flow through the boiler must be maintained The recommended maximum temperature difference between the boiler supply and return water is 40 F However a maximum delta T of 80 F across the boiler is allowable A minimum boiler supply water temperature of 130 must be maintained to avoid sustained condensing within the combustion chamber Primary Secondary Piping If the conditions above cannot be met then parallel piping systems must be converted to an arrangement that will provide the proper water flow through the boiler at the proper temperatures Primary Secondary piping is a common method for isolating the boiler from the system The concept must be for the boiler loop to inject heat into a primary loop provided the return water into the boiler is at least 80 F A by pass containing two closely spaced tees must be installed to de couple the boiler loop from the primary loop see Figure 51 The converted system should resemble Figure 52 Care must be taken to avoid dead heading the system pump Conversions should be reviewed and approved by a Consulting Engineer or other qualified professional to avoid system deficiencies BY PASS PIPING 4X D TO mnl j FROM ORIGINAL ORIGINAL ZONES ZONES FROM TO BOILER BOILER ENVELOPE ENVELOPE NOTE
15. 2 w e 2 01 oy NOLLVINHOHNI AHOLOVA LINSNOO AINO SNIVH L SVO QUVONVLS UOJ 554 L3 INI WAWINIA xxx TIO SVD 5 SILVY WNWININ NMOHS S31VH xx SONILL3S 55 S3ZIS 3 IZZON VIVO H3NHf8 10 33S SSdud L3 INI 331L LV IWOLLOG 401 SVD 1300WN 4 SVO SSdud Q IOJINVIN ONILLAS uasndalg WNWININ SVO LYN XOHddV HOIH XOHddV H3NHRI8 IO 24 Sec uoneuiquio 2AIX 75 SECTION VIII REPAIR PARTS All MPC Repair Parts may be obtained through your local Burnham Commercial Cast Iron Wholesale distributor Should you require assistance in locating a Burnham Commercial Cast Iron distributor in your area or have questions regarding the availability of Burnham Commercial Cast Iron products or repair parts please contact Burnham Commercial Cast Iron Customer Service at 888 791 3790 or Fax 877 501 5211 Pz RNS as L XA ERASER 4 22 Y FA S X Woy V
16. CPC 2 Locate four 4 C I burner swing door BSD hinge latch castings two 2 C I BSD hinge loop castings ten 10 7 16 split lock washers and ten 10 7 16 14 x 1 1 2 12 cap screws Front section and burner swing door BSD designed to use universal parts that can be mounted to make the hinge set work for either left hand or right hand swing For the purpose of these instructions Burnham will default to mounting hinge set for left hand swing left side 3 Determine best hinge arrangement for your installation based on room size piping arrangement burner fuel lines utilities and service clearances 4 For BSD left hand swing left side hinge a Install hinge latch castings pin side up on hinge pads located on left side of front section Use two 2 7 16 split lock washers and two 2 7 16 14 x 1 1 2 lg cap screws per hinge pin see Figures 9 and 10 Secure hardware wrench tight b Install hinge latch castings latch side up on hinge pads located on right side of front section using same hardware for hinge latch as was used for hinge pin see Figures 9 and 10 Secure wrench tight HINGE PIN SIDE UP HINGE AT LATCH SIDE UP c Locate and position burner swing door BSD vertically against wall or structure to allow access to both side front and rear insulation side d Install hinge loops inside hinge pockets located on left side of BSD by engagin
17. WARNING Failure to supply adequate air to the boiler will result in unsafe boiler operation For commercial and industrial equipment permanent facilities for supplying an ample amount of outside air shall be provided in accordance with the following For boiler rooms adjacent to outside walls and where combustion air is provided by natural ventilation from the outside there shall be a permanent air supply inlet having a total free area of not less than 1 sq in per 4 000 Btu per hr 35 sq in per gal per hr 5 5 cm2 per kw of total input rating of the burner or burners and in no case less than 35 sq in 0 425 m2 For boiler rooms not adjacent to outside walls the combustion air shall be supplied in a manner acceptable to the authority having jurisdiction 5C X 6 7 STEEL CHANNEL OR 1 4 X 4 STEEL PLATE CUT TO PROPER LENGTH L MINUS 16 T CONCRETE NO OF PAD SECTIONS 4 THICK Didi CONCRETE PAD 4 43 1 4 5 50 6 56 3 4 7 63 1 2 70 1 4 9 7 83 374 gt 11 90 172 2 97 1 4 2 104 E 4 110 3 4 BE RECESSED SM TO P M 15 117 1 2 INSIDE END OF CHANNEL I 16 8 137 3 4 431 RARE 297 Figure 2 Boiler Foundation 14 a In the absence of local requirements the id 24 confined space shall be provided with two i permanent openings one in or near the top of 5 MIN the room and one near the
18. 3 remove knockout on casing closest to mounting Ai PEERS 4 5 hole Connect end of harness with forked 2 terminals to casing knockout Connect blue 1 wires to terminals on limit control wires are HARNESS 20 interchangeable Refer to Figure 43 Figure 41 Install Probe Low Water Cut Off 54 p dm 14006 LOW FIRE SUPPLY MANIFOLD X HOLD CONTROL 1 2 IMMERSION WELL REAR OF BOILER FRONT A BOILER Figure 43 Install Low Fire Hold Control c Connect opposite end of L4006B Low Fire Hold Control harness to right side junction box cover hole location 2 as shown in Figure 40 d Locate mating connector labeled Low Fire Hold inside right junction box Join mating connectors which are polarized and lock together Lightly tug on connectors to make sure they are secure e Proceed to next appropriate control option listed below for installation details If no other controls are being installed at this time secure Cover A and Cover to jacket rear top panel with two 2 8 x 1 2 1g hex head SMS per cover Install 7 8 knockout plugs provided to all unused holes refer to Figure 40 4 Install Low High Low Control or Modulating Control a Install Low High Low Control as follows for modulating control proceed to Step b i Apply thread sealant to 3 4 immersion well and install in Tapping as shown in Figure 38 Wrench well until water tight ii Loca
19. L cL OF 60 80 20 90 S0 70 XL 7828 HX Al Wes BT X ub 882 Wel oelg Or HOS eiddiN 06 7829 206 9 1 1001S MA X 9L SE9 0L4 09649409 929 al X Ze 9L v 19 014 ODBIqUOD 28 15 08 Jolley AL Oh ab XL lg HX Al VIS AVX Al OL 67 56 X NI 5 eiddiN 206 1 7019 006 X AL 919 206 1 A19 006 19 xoe g 1021S 21 90 19 01 02810002 7016 Al X MAL 60 9 19 01 02810000 OLG X GO GLO OL 09649409 ALG X e GO VL9 OL 09649409 VIG 15 06 WIL 9 55 9NDIHOM TWNOILdO uonduoseq 3HnSS3Hd ONIMYOM 1OHINOO 8 5 SLYVd HiVd3H c8 274 29 eS 18 12 19 16 101 IOHLNOO MOT jeuondo 59 4 7031405 ONILVINGOW 927 G IO3INVIA IOHLNOO G IO3INVMW 5 G OAINVIN G IO3INVIN AlddNs 1041NOO
20. as shown in Figure 38 b Remove 2 knockout from bottom of Wrench well until water tight 750P LWCO control case Connect end b Locate LA006E High Limit Control and of harness with forked terminals to casing remove knockout on casing closest to mounting knockout see Figure 41 Connect wires to hole Connect end of harness with forked terminal block as follows terminals to casing knockout Connect orange Terminal 1 Black Wire w Red Tracer wires to terminals on limit control wires are Terminal 2 Pink Wire interchangeable Refer to Figure 42 Terminal 3 Red Wire w Black Tracer Terminal 4 Brown Wire Terminal 5 Violet Wire c Mount LWCO Control on probe and tighten screws SUPPLY MANIFOLD HIGH LIMIT CONTROL HARNESS nmm m m C d Connect ring terminal on black probe wire from circuit board to terminal on probe and tighten REAR OF n wing nut BOILER 28 e Connect opposite end of M amp M 750P LWCO control harness to left side junction box cover hole location 7 as shown in Figure 40 22 a 3 4 It may be necessary to clip the conduit BOILER IMMERSION connector nut and flex it slightly to slide it over the control harness connectors Nut should still DE en be able to be tightened against cover plate HIGH LIMIT f Locate mating connectors labeled SUPE Power and LWCO Contacts inside left Figure Inst
21. 3 8 16 X 3 1 4 LG THREADED ROD ASSEMBLED END VIEW TYP BOTH SIDES Figure 17a Front Center Section Horizontal Channel Assembly w Mounting Hardware 2 3 8 HEX NUT 4 3 8 FLAT WASHER N 3 8 16 X 13 3 8 LG THREADED ROD gy oe 7 16 X 2 5 8 LG SPACER ASSEMBLED END VIEW TYP BOTH SIDES Figure 17b Rear Section Horizontal Channel Assembly w Mounting Hardware 32 MOUNTING LUG CHANNEL BRACKET FLEXED OPEN FRONT CENTER HORIZONTAL CHANNEL ASSEMBLY WASHER RETAINING DETAIL A TYP BOTH LUGS 2 A INTERNAL WASHER FRAME MOUNTING BOTH LUGS FRONT OR CENTER SECTION SEE DETAIL amp B REAR SECTION CENTER SECTION MOUNTING LUG MOUNTING LUG FS WASHER RETAINING NS gt 7772272 22222222 zzz pm 227213 DETAIL A TYP BOTH SIDES INTERNAL WASHER DETAIL B TYP ALL LUGS gt REAR HORIZONTAL CHANNEL ASSEMBLY FRAME MOUNTING LUG REAR SECTION ASSEMBLY SEE DETAIL amp Figure 18b Mount Rear Section Horizontal Channel to Block Assembly 33 5 8 FLAT WASHER Y 5 8 HEX NUT LOWER FRONT CENTER SECTION BRACKET FRONT OR CENTER SECTION LEG 5 8 FLAT WASHER 5 8 11 X 1 1 2 LG HEX HEAD BOLT Figure 19 Attachment of Lower Front Center Sectio
22. 4 THRU 6 SECTION BLOCK SUPPLY MANIFOLD DR NN 5255 6 2 BE NA Cu LN NN NN Y Y Sees IP E S 3 d S SS S S 74 V SN 7 5 21 YING e NNN ANNA NE Q Y 7 a EN f X 3 Watt mz YOO SME EN m i SS WRAPPER WRAPPER FRONT MODULAR INSULATION WRAPPERS 7 THRU 18 SECTION BLOCK Figure 60 MPC Heat Exchanger Insulation Wrapper 50 098101 1 v 0v X g Ly X PUIWON MUL Ov 20 088101 61 v 0vL X GE X BUIWON MUL At 10 088101 61 v 0vL 1 82 X EUWON XUL Vt 20 188101 61 V E OVL X PUIWON MUL AE 10 1680 61 v 0vL X X PUIWON YUL VE uoneinsu 1910902 20 678 101 61 V E OVL 8 1 86 X PUIWON MUL 702 0 6 8101 61 v 0vL X 8 6 16 MUL 782 10 678 01 61 v 0vL X 8 9 X PUIWON MUL
23. 491105 035914 81 D 10 06 20 d 5 E Eun 482 D 20 88 201 NVTIU23 434914 81 D 10 06 201 NV 1102 034914 LWAY 382 20 42400 499 IWM D 10 88 001 08201 11235 422 D 10 88 201 aV 1102 039914 IWAMA D 10 062207 91112 359714 2 20 42400 2 D 10 88 001 21 08201 11235 21 7 033914 2 1 10 682201 97709 034914 LWAS D 10 68 20 Sad TO E i 91109 4384914 LWA3 81 10 06 20 702 0354914 81 D 10 06 20 S 549717109 9354973 10 682201 ___ 1 D 0 88Z20T 491105 14 184 D 20 2400 499 INAM D 10 827001 01 08201 1235 01 591105 034914 10 06 20 491105 035914 10 687201 ___ 481 D 60 88 201 49717109 GIAVA LWAY Te CD 10 2 00 3493 D 10 827 001 60 08201 NUIL23S 6 9349714 81 D 0 06 20 IWAN 482 D 20 88 201 397709 9349713 LWAS 81 D 10 062201 11 2 034914 LWAY 4812 D 10 2400 999 IWAY D 10 82 001 80 v08201 1235 8 IWAN D 10 88 201 597709 CIV LWAA D 110 06 201 033914 D 10 727001 dvd LWAY D 10 82Z001 70 08201 1
24. 9 16 SPLIT LOCK BURNER SWING DOOR B S D SHOWN CLOSED Figure 34 Secure Burner Swing Door for Tight Perimeter Seal BURNER SWING DOOR _ 8 5 0 3 1 4 THICK 8 5 0 INSULATION BURNER ADAPTER PLATE GASKET BURNER ADAPTER PLATE __ 1 2 SPLIT LOCK WASHER 1 27 13 NUT 3 8 16 X 7 8 HEX HEAD CAP SCREW COMMERCIAL BURNER Figure 35 Install Burner Adapter Plate and Burner to Burner Swing Door 50 P DIA IDENTIFICATION BOLT CIRCLE NUMBER DIA ND HOLE EU STANDARD BURNER ADAPTER PLATE Figure 36 Burner Adapter Plate Options Power Flame C Series Burner Adapter Plate Boiler Model Part No MPC4 thru 602263401 74 2 10 1 4 MPC8thru 14 602263411 41 9 12 MPC15 thru MPC18 602263421 42 10 3 8 14 1 8 Power Flame JR Series Burner Adapter Plate Boiler Model Part No 1 most cases the burner adapter plate carton for the specified burner will be provided by Burnham 2 If adapter is provided by Burnham open carton and remove contents Apply four 4 small dabs of silastic on rear surface of adapter plate to temporarily hold gasket in place Hold adapter plate in position against burner swing door align holes and secure with four 4 3 8 lock washers and 3 8 16 x 7 8 lg cap screws 3 I
25. CLOSELY SPACED TEES MUST BE WITHIN 4 PIPE DIAMETERS OF MAIN CIRCUIT Figure 51 Parallel Piping Conversion Multiple boilers are installed the same as single boiler installations Each boiler loop will contain its own boiler circulator see Figure 49b The boiler circulator selection will maintain a constant and minimum flow through the boiler during every heat demand The circulator must be properly selected based on the design temperature between the boiler supply and boiler return boiler circulator must be used with a primary secondary piping arrangement PRIMARY LOOP Heating amp Cooling Refrigeration Systems SECONDARY LOOP S BOILER LOOP Figure 52 Typical Burnham Boiler Primary Secondary Loop System Alternate Piping Arrangements Piping arrangements other than Parallel and Primary Secondary such as System Bypass are acceptable as long as they ensure that the flow and temperature requirements of the boiler are met Glycol Antifreeze Solutions Many systems today use ethylene or propylene glycol antifreeze solutions as a measure for freeze protection as well as a pump lubricator and corrosion inhibitor The properties of the glycol mixture have an impact on valve and pump sizing All glycol solutions have a lower specific heat than water This means that the glycol solution cannot transfer heat as well as pure water resulting in the need for higher flow rates In addition the viscosi
26. For proper installation use and maintenance see all applicable sections of the Installation and Operating and Service Instructions Manual furnished with the unit 5 This warranty does not cover the following a Expenses for removal or reinstallation The owner will be responsible for the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith and transportation to and from Burnham Commercial Components that are part of the heating system but were not furnished by Burnham Commercial as part of the commercial boiler Improper burner adjustment control settings care or maintenance This warranty cannot be considered as a guarantee of workmanship of an installer connected with the installation of the Burnham Commercial boiler or as imposing on Burnham Commercial liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation which liability is expressly disclaimed o Pub BCL1109041 Boilers parts or accessories installed outside the 48 contiguous United States the State of Alaska and Canada f Damage to the boiler and or property due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instruction manual g Any damage or failure of the boiler resulting from hard water scale buildup or corrosion the heat exchanger Any damage ca
27. Minimum valve size per ASME Code is 3 4 NPT 5 Swing joints may be piped over the top 106 9 of the boiler if space is limited 116 1 6 System design must accommodate the above Boiler Operating Requirements 7 Diaphragm expansion tank shown but other types of air elimination systems may be used Figure 49a Recommended MPC Minimum Piping Single Boiler Application 59 ojdninjy 6 9 11614 061 A ddng 4008 L 108 UNPA sSjuouroambos 19104 Cop INSI 0 5 juej rodui 19U70 pue sdoap 59715 odid 404 LA xri 43108 83 W31SAS NOLLVNIATT3 30 3dAL MOlvinoMIO M3HlO MO 43408 NOISNYdX3 WovsHdavia n 4 JAVA 340 3 ANWA 38019 M3Q V3H SV EE 3215 AWVS 303H2 A ASIN anna 0109 W3lSAS dans S 1 31545 a REA EO L 1 iv V 1 s uaivaH S s31v3H v YILYM M3IVM 193MIONI WONJ 01 Xlddfls e Boiler Operating Requirements Minimum Return Water Temperature 80 F e Maximum Delta T 80 F Mi
28. Place the rear section in its approximate final position as outlined in Section I Stand rear section up and brace in vertical position with a suitable prop See Figure 6 Step b Clean the rope groove around perimeter of the rear section with a wire brush Step c Open the Boiler Assembly Carton s marked and remove contents Separate the items by type There are two 2 different pre cut lengths of the red silicone coated fiberglass rope The combustion chamber rope is 86 long and the perimeter rope is 164 long Step d Using the multi purpose spray adhesive provided apply the adhesive to the perimeter rope groove Follow the directions on the can for application and tack time GREAT CARE MUST BE TAKEN TO ENSURE THAT THE ADHESIVE DOES NOT COME IN CONTACT WITH THE MACHINED NIPPLE PORTS Step e While the adhesive is becoming tacky clean the nipples ports and nipples thoroughly with a de greasing solvent Step f Locate a 164 length of silicone coated fiberglass rope and 10 3 oz cartridge of RTV 6500 or RTV 736 Red Silicone Sealant Starting at 3 o clock position push rope into groove and continue around perimeter until rope overlaps the starting point Rope should be approximately WARNING Sealant must be properly applied to ALL boiler joints Failure to properly seal the boiler joints will result in combustion gas leaks through the joint DO NOT operate boiler with combustion gas leaks The sealant shou
29. gaps at the locations identified in Figure 8 Unless specified otherwise gaps should be only measured at these locations A maximum gap of 025 KEEP NIPPLES ALIGNED WITH NIPPLE PORTS If necessary tap edge of nipples lightly with a blunt tool or rod to keep nipples from cocking while sections are being drawn up DO NOT DRAW UP SECTION WHEN NIPPLES ARE COCKED If the torque required becomes excessive periodically place a heavy block of wood over each nipple port and strike as squarely as possible with several blows to relieve tension on the draw up rods Step o Remove Draw up Rod Assemblies and set aside Step p Prepare center section on block assembly to receive next casting see Figure 5 Clean the rope grooves around the combustion chamber and perimeter of the section with a wire brush Repeat Step d through step with the following exceptions e During Step 4 procedure apply multi purpose spray adhesive to combustion chamber rope groove as well as perimeter groove e During Step procedure locate 86 length of red silicone coated fiberglass rope Starting at 9 o clock position push rope into groove and continue around combustion chamber until rope overlaps starting point Mark joint cut off excess and seal joint per instructions e During Step 4 procedure apply sealant to the 6 flueway sealing grooves on the center section BE SURE TO APPLY THE SILICONE COATED FIBERG
30. wid 49 QOH 138 NS 1 USHSVM 1 14 SLVW1d 558 4 Js 286 1 4 03043 1 27 Z X LAN H3HSVM 1 14 B S 008 8 5 8 8 S LAN ONITANOD 8 6 NOILOSS S GO NOLNALSY 8 5 YaHSVM 19713 8 5 19 CUT BRACE ENDS 45 ANGLE SEE DETAIL A _7 DRILL 1 2 DIA HOLE 474 a 22 2 22 5 DETAIL REAR SECTION 3 8 16 X 2 1 2 LG BOLT A 2 X4 WOODEN BRACE CONCRETE PAD WITH 5 CHANNELS OR SKID PLATES 2X4WOODEN FLOOR PLANKS CASTING LEG TO WALL OR OTHER 3227 STRUCTURE Figure 6 Vertical Bracing of Rear Section 7 NIPPLE MACHINED FACE OF 25 NIPPLE PORT 97 2 7 NIPPLE J MACHINED FACE OF Wut EX NIPPLE PORT gt VERTICAL L AXIS REFERENCE HORIZONTAL 29 Acc 7 AXIS NIPPLE NIPPLE NIPPLE GAUGE Figure 7 Setting of Nipples Y gt BOTTOM BOTTOM LEFT RIGHT REFERENCE REFERENCE PAD PAD Figure 8 Inspection Pad Locations for Section Draw up 20 WARNING This is a forced draft fired boiler and sealant must be applied where specified for proper and safe performance Burnham Commercial has approved section joint sea
31. 1 4 Intermediate Top Panel 11 Section 35 3 4 Front Top Panel 11 3 8 Rear Top Panel 12 Section 20 1 4 Intermediate Top Panel 11 3 8 Rear Top Panel 17 Section 2 35 3 4 Front 7 Intermediate 27 Intermediate 27 Intermediate 11 3 8 Rear 18 Section Top Panel Top Panel Top Panel Top Panel Top Panel JACKET FRONT TOP PANEL a et JACKET OUTER TOF 4 LOCKING TABS CORNER PANEL JACKET INTERMEDIATE TOP PANEL FRONT FRAME RAIL JACKET FRONT TOP PANEL DETAIL A SUPPLY MANIFOLD 88 X 1 2 LG HEX HEAD SMS JACKET OUTER TOP INTERMEDIATE PANEL FRONT FRAME RAIL Figure 30a Installing Jacket Top Panels Viewed From Front Step 1 Position front panel at approximately 30 top corner panel and secure front flange to clips angle hook front flange under clips on outer top with two 2 8 x 7 hex head SMS as shown in corner panels as shown in Figure 30a Detail A Step Figure 30a Secure rear flange to outer top corner 1 Lower rear of panel into position between outer panels with two 2 8 gt 1g SMS as shown in Figure 30b 46 JACKET FRONT TOP PANEL 8 X 1 2 LG HEX HEAD SMS Figure 30b Install Jacket Top Panels Viewed From Rear SLOTTED OPENINGS FOR LOCKING TABS JACKET OUTER TOP CORNER PANEL SUPPLY MANIFOLD JACKET OUTER TOP INTERMEDIATE PANEL JACKET OUTER TOP INTERMEDIATE PANEL Figure 30c Install Jacket Rear Top Panel Vi
32. 1105 91 4 vl Z d 42 202 4001 asa 1 10 701 V V Vv VY V v V V uore eDutH asa 1819808 V V V V V V Y peie d 6 61 8 4 81 9 9 11909808 t t YY SSN 4euseM Wld 91 56 01 J9AO no ues joyse Z 2 Sse 9 X X pereo auos m 6 1066810 19 SED 8 970901 Z Z 8 Z 3 8 d c X X 8 6 2 vB 8 J8A0D 1 0 9 1529 575509908 E b E E E E E E E E LE H sse g ANDS 4 60619808 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 MeJog de XH 67 1 1 91 88 9 81909808 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 peield SSN 1614 8 6 8 10 001 b P d 10129109 UOI 1529 101591100 20 92910 20212 02012227 02501727 pereo 1 b b b 1 LE Lb b LE 19 2 10774090 8 Z 9L SL vL EL OL 60 80 Z0 90 SO ide UN SIN3NOdWOO 4
33. 45 55 Figure 46 56 Figure 47 57 Section IV Installation Instructions Figure 48 58 Figure 49a 59 Figure 49b 60 Figure 50a 61 Figure 50b 62 Figure 51 63 Figure 52 63 Figure 53 63 Figure 54 64 Section V Operating Instructions Section VI Service Instructions Section VII Burner Specifications Discharge Piping for Pressure Relief Valve 105 Appendix Figures continued Figure Number Section VIII Repair Parts Page Number Description 106 Figure 55 76 MPC Cast Iron Section Assembly Description 77 Cast Iron Section Assembly Figure 56 78 MPC Common Bare Boiler Components Description 79 Common Bare Boiler Components Figure 56 80 MPC Common Bare Boiler Components continued Description 81 Common Bare Boiler Components Figure 57 82 MPC Front amp Center Section Frame Rail Assembly Description 83 Front amp Center Section Frame Rail Assembly Figure 58 84 MPC Rear Section Frame Rail Assembly Description 85 Rear Section Frame Rail Assembly Figure 59 86 MPC Return Water Mixing Tube RC Assembly Description 87 Return Water Mixing Tube RC Assembly Figure 60 88 Heat Exchanger Insulation Wrapper Description 89 Heat Exchanger Insulation Wrapper Figure 61 90 Internal Wiring Harness Components Description 91 Internal Wiring Harness Components Figure 62 92 94 Jacket Panel Assembly Description 93 95 Jacket Panel Assembly Figure 63 96 MPC 2nd and 3rd Pass Flueway Baffles Description 97 MPC 2nd a
34. 66 789 L0 59 001 2 2 61 42 7 9 Sjexoeug 9 2194109 do 1 9 10 22 101 19409 1405 1exoer 10 80101 M Assy Jeueg aye 10 60101 M Assy 407 1ewoef Vt 81009808 OL OL 86 86 85 85 86 9 9 92 97 97 86 82 86 peor 4 dc 2 p 6 10 227101 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 eje d 10 00 QUE J 14014 1exoer 10 92001 14014 1 81 11 9 Gk vL 61 OF 60 80 20 90 60 0 ON ON Hed uonduoseq way A18W3SSV TANVd LAMOVE SLYVd 93 Figure 62 Jacket Panel Assembly continued 10 05 001 jexoeig 19400 qsg PALF 61 L0 672001 Assy 19400 188 10014 jexoer 81 L0 87Z001 Assy 19400 10044 10 079 101 41 yoelg 2829618 9L 91 21 8 8 8 8 8 99 28 S1 6601 gS
35. bottom The openings shall communicate by means of ducts with the E Y 1 1 1 outdoors or to such spaces crawl or attic that communicate with the outdoors i Where communicating by means of vertical ducts each opening shall have a free area of not less than 1 sq in per 4 000 Btuh 35 sq in per gph 5 5 cm2 per kw of total input rating of all appliances in the enclosure ii If horizontal ducts are used each opening shall have a free area of not less than 1 sq 011 in per 2 000 Btuh 70 sq in gph 11 cm2 per kw of total input of all appliances in the enclosure 5 CHIMNEY OR VENT Be sure to read below WARNINGS The Model Series boiler is designed for forced draft firing and may be used with a A T conventional natural draft stack 15 minimum height or a stub vent sometimes called a diesel Figure 3a MPC with Rear Outlet Vent stack see Figure 3a See Table I for the proper vent outlet size For low silhouette vent terminations see Figure 3b Draft controls are not normally required although they may be used on installations where a natural draft stack is used or on multiple boiler installations with a common stack For proper operation boiler must maintain positive pressure of 0 1 W C at the breech in the cast iron flue collector during burner high fire operation see breeching pressure sensin
36. flanges on channels Always DS D 9 Section CUT CUT CUT CUT position harness between holes 6 Determine routing of harness and secure to front 10 cur frame channel rails based on burner swing door 11 Section cur BSD hinge arrangement determined previously 12 CUT Harness can be secured to suit any of the following arrangements a BSD with left hand hinge arrangement harness 15 Section OUT 2 of jacket front panel en route to 16 Section cur cur b BSD with left hand hinge arrangement harness 255000 22 12 41 21 exits right side of jacket front panel en route to control panel SECURE HARNESS TO LEFT VERTICAL RAIL BSD W LEFT HAND HINGE SET UP SECURE HARNESS TO RIGHT VERTICAL RAIL BSD W RIGHT HAND HINGE SET UP 2 CABLE CLAMP 2 8 X 1 2 LG HEX HEAD 5 5 FRONT FRAME LA RAIL LOOP EXCESS HARNESS LENGTH AS NECESSARY Figure 24g Internal Wiring Harness Components Secure Harness to Vertical Channel 41 BSD with right hand hinge arrangement harness exits right side of jacket front panel en route to control panel d BSD with right hand hinge arrangement harness exits left side of jacket front panel en route to control panel Locate two 2 cable clamps and secure harness to vertic
37. in place in their respective order until all sections are in the assemblage Ground surfaces between adjoining sections should be spaced 3 8 to 1 2 apart Spacing of more than 1 2 will limit number of sections that can be drawn up in one unit and could indicate cocked nipples WARNING Sealant must be properly applied to ALL boiler joints Failure to properly seal the boiler joints will result in combustion gas leaks through the joint DO NOT operate boiler with combustion gas leaks The sealant should be applied before each section is placed on the assembly On long boiler assemblies it may be necessary to draw up a partial block if the entire boiler is not ready to be drawn up tight within two 2 hours of the first application of the Silastic If the block assembly time extends overnight the partial block completed must be drawn up tight before leaving the boiler overnight If a joint springs apart it must be re drawn tight within two 2 hours of first application of Silastic to the joint Step c From the Hydraulic Draw up Kit locate and assemble one 1 set of draw up assemblies that each include 34 x 23 12 threaded rod s 34 coupling nut s if applicable the appropriate pressure plate washer and 34 hex nut as shown in Figure 5 Insert one 1 assembly through each of the 3 and 4 NPT bosses on rear section until pressure plate is tight against the boss Locate and place the 8 di
38. limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to boilers parts or accessories designated as commercial grade by Burnham Commercial and installed and used exclusively for purposes of commercial space heating or domestic hot water generation through a heat exchanger or a combination for such purposes and do not apply to residential grade products or industrial uses 2 Components Manufactured by Others Upon expiration of the one year limited warranty on commercial grade boilers all boiler components other than heat exchangers manufactured by others but furnished by Burnham Commercial such as oil burner circulator and controls will be subject only to the manufacturer s warranty if any 3 Proper Installation The warranties extended by Burnham Commercial are conditioned upon the installation of the commercial grade boiler parts and accessories in strict compliance with Burnham Commercial installation instructions Burnham Commercial specifically disclaims liability of any kind caused by or relating to improper installation 4 Proper Use and Maintenance The warranties extended by Burnham Commercial conditioned upon the use of the commercial grade boiler parts and accessories for its intended purposes and its maintenance accordance with Burnham Commercial recommendations and hydronics industry standards
39. rear section Sealant should start against the rope gasket run across the groove in one continuous bead and end against rope gasket at the opposite side Refer to Figure 5 Ajquiassy uonoes 40 6 9 11614 135 dWna 791 62 X P E 1 LAN E H3HSVM LV 133205 13 5 0 3dOH HON3HM eA W3HSVM 11714 p e NOLLWNISINOD t INN 5 8 3dOM NOLLSQSWOO 29 i 31V Td 8 55384 SNOLLOSS 31N32 S3AOOHN9 1 1 36 9 224 1 H32vdS 21797 AN 75 9 dos OUEZ X v S Y 235 5 1Nv1V3S SEA WACUR WAR X 8 bw aN 5538 24 LZ ZA N3HSVM LYH LAN AAYAH 1 LNVHO 33 gt ALO SNOILO3S H31N32 E IVd 553 49 W3HSVM 1913 FE LAN shie 297 EZ X Fda iN ad 008 IVANYW HOS 1913 IE W130 33 3unssaud
40. uonejnsu JeddejA 1 104 Z 90 928 10 61 v 0vL 8 1 9 MUL OL 90 928 10 761 0 X 8 6 XUL gl 70 958 101 61 v 0vL 8 8 26 X EUIWON XUL VI uoneinsu JeddejA 1 oN ea 8 ZL 91 vi 6 cL OF 60 80 20 90 90 0 uonduoseg H3ddVHM NOILVINSNI HH39NVHOX3 1V3H SLYVd HiVd3H 89 SUPPLY MANIFOLD al Wiring Harness Figure 61 MPC Intern 2209618 e EP DE M EC 10 gg O 0909818 SL 6 6 6 6 6 9 9 9 uepnnb3 WS2S AL 891 MEI ALL 6 60 886 1 0 1 1 1 L 8LOdIN MUL IOAN 728 20 8 7 LOL Lo b OE 4 ELOdW MUL 88 L0 8 vL0L GENE MEUM MUL vOdlN V8 euu 8 61 91 100 9980 16 2 uo p97 2 19915 WS 105 10 48101 OL OL 8 8 8 8 8 9 9 9 9 9 v v Vv 51 2 2 0 9 80 61510 uw lL BT 902 1 22 OS 0 61910 2 L zZ z L 61 91 L 22 46 10 618101 67 91 6 02 WS uoisua x3 Aem aseyD 0 ZEv LOL 61 91 1 19 Ov 20 26 101 bo Lo b 4 Lo 61 91 8 v
41. x 1 2 hex head screws 27 491105 035914 2 10 68201 D 20 88Z201 597709 4 14 81 D 10 062201 2 034914 10 06 20 999 D 10 88 001 81 08201 011935 8 491109 033914 LWAY 0110 2800 491105 34914 2111 lt gt 10 68 20 fee D 10 88 201 597709 03 14 LWA3 D 10 062201 x97703 034914 10 06 20 499 1 D 10 88 001 1 08201 1193 11 491105 035914 1 CD 10 2 001 491105 0354914 LWAS D 10 68 201 397709 034914 Ke 10 68120 9110 034914 LWAs3 81 10 06490T 11 2 939974 81 e 10 06 201 m3 5 591105 438914 LWAS AZT 2 10 68 20 _ 488 D 20 88 201 597709 34 14 LWAA 81 D 10 06420 dv3 IWM D 10 827001 08201 11235 491105 034914 LWASN 10 06 201 WAY D 20 882201 EI IS A LAAI 1056820 29717109 0354973 IWM K 20 424001 LWAY D 10 82 001 08201 11235
42. x 1 2 sheet in bracket metal screws 4 8 X 1 2 HEX HEAD N SHEET METAL SCREW HORIZONTAL CHANNEL ASSEMBLY X PILOT HOLE CASTING 1 7 1 VERTICAL SIDE CHANNEL PAINTED BLACK LOWER BRACKET _ Figure 21 Securing Frame Side Channels to Horizontal Top Channel and Lower Brackets Center Section Shown 35 FLANGE TURNED OUTWARD DETAIL B DOUBLE HOOK CENTER BRACKETS FLANGE TURNED INWARD LOWER REAR BRACKET 2 BU RS LOWER FRONT Y CENTER BRACKET SEE DETAIL DOUBLE HOOK DETAIL A SINGLE HOOK FRONT amp REAR BRACKETS TIE BAR 36 13 Figure 22 Lower Tie Bar Installation Repeat operation until all vertical channels have been installed Using an open end wrench and ratchet with socket tighten all 5 8 bolts and nuts to secure frame brackets to casting legs Locate Jacket Carton s marked JC 2 and remove contents Install lower tie bars into slotted openings on lower frame brackets to provide proper spacing between frame channels refer to Figure 22 Determine proper location of tie bar by comparing it s length to the distance between brackets Lay each tie bar on the floor at that location along both sides of boiler Step a Starting at the rear and working to the front hold the firs
43. 08 AL 7808 WX Al xoejg Buronpey X AL 7202 61 ab GOL BT AEX Sy Ov HOS eiddiN 006 X AL 7209 206 1 7809 006 7 09 1 1994 ALX MAL 0L 919 014 ODBIQUOD 7006 X OL GLO OL 02810002 7806 Ze OL VLO OL 09644409 vog 18 09 SALA ISd 001 0 7 einssejg einejeduio uomne nsu X WLLBETL UO SIOWUW GLOZV90071 uonduoseq 3HfiSS3Hd 9NPIHOM IWNOILdO 1IOHINOO 9 WIHL QHVGONVIS 08 0Z 09 0S 07 06 0c 01 99 penunuoo ISd 09 PUL 15 OE pue WHL 64 0 p1epuels 59 1 4 U3 104 us NHV3MW Q IO3INVIN ATddNs 100 129009908 404009908 920009908 860009908 714109908 109109908 99509918 99509918 655009908 129009908 404009908 910009908 820009908 920009908 850009908 219109908 919109908 719109908 105109908 86609918 75509918 85509918 16609918 ON Hed 81 2 91 91 vL
44. 2 Adjust cable lengths to lift at approximate center of gravity per chart Figure 48 Packaged Boiler Shipping Information FORK TRUCK OPENINGS SEE NOTE 4 58 Boiler Operating Requirements Minimum Return Water Temperature 80 F Maximum Delta T 80 F Minimum Supply Water Temperature 130 F SYSTEM PUMP bo 40 9 SUPPLY B BOILER CIRCULATOR 4 SUPPLY MANIFOLD 4 RETURN MANIFOLD CLOS P TEES XN ISOLATION VALVE 1 Supply Water Side Press Drop Inch Ft Wtr we 3 99 __ 10 3 REAR OF BOILER 2 Return 40 F Rise Water Side Press Drop Ft Wtr E Pa ELY SPACED Xi go ISOLATION VALVES CIRCULATOR SUPPLY INDIRECT WATER HEATER S IWH RETURN CHECK VALVE RETURN FROM pd INDIRECT WATER HEATER S IWH ISOLATION VALVE lt DRAIN VALVE SEE NOTE 4 NOTES 1 All piping is schedule 40 Flow 2 Pipe sizes listed are based on a 20 F Rate or 40 F Delta T temperature rise GPM across the boiler Select one to match application 3 When specified supply return piping size is less than 4 install appropriate size reducer directly onto boiler supply and return manifolds 60 5 65 4 Drain valve ball valve preferable gate valve acceptable alternative supplied by others
45. 235 491105 034914 LWAS D 10 68 20 x 81 D 20 882201 493 D 10 88 001 90 08201 1235 9 917105 035914 8T D 110 06 201 482 D 20 88 20 497709 039914 M LWAY D 10 06 20 2 IWMY D 10 88 001 S0 v08201 1235 6 IWAN fee D 10 88 201 AVIN 9359714 IWAMA 81 D 10 06 20 2 D 10 88 001 0 08201 1235 NOILdIHOSAC ALD N d ALD N d ALD ALD N d NOLUVO 8716 HWXIIOH ATANASSV MIOTA LNOdd 1 55 OW LAMY OH LINMY eqni unie 91461 28 SUPPORT COLLAR SUPPORT CLIP FRONT RWMT END CAP DETAIL 4 RETURN MANIFOLD ALIGNMENT HOLE FOR POSITIONING PLUG RWMT POSITIONING PLUG 2 REQ D TUBE RWMT WITHOUT RETURN WATER MIXING FLARED COLLAR RETURN WATER MIXING TUBE S W FLARED COLLAR 4 SUPPLY MANIFOLD RWMT END CAP SEE DETAIL 3 RWMT FRONT SUPPORT PLUG 9 4 a ra I 8 X 1 2 SS HEX HEAD SCREWS BLOCK ASSEMBLY Figure 13 Return Water Mixing Tube RC Assembly and Installation 29 Repeat this process for each joint securing the 6 Thread upper and lower positioning plugs into 1 2 previous assembly to the tube show
46. 275 60045 10e ars cres s 25 ao 65045 wo as crasoo ornan s o st 2 75 6 wo 260 crasoo ornan 2 60 225 800 45 Table Beckett Gas Burner Specifications BURNER BURNER DAMPER SETTINGS MANIFOLD PRESSURE MINIMUM BOILER BURNER WC INLET MODEL MODEL LOW HIGH LOW FIRE HIGH PRESSURE FIRE SHUTTER BAND 5 WC E pese o o 59 O SSS 8 NOZZLE DATA MPC5 MPC6 MPC7 MPC8 lt m 7 7 16 17 18 Table Power Flame 2 Oil Burner Specifications BURNER BURNER APPROX HIGH FIRE HIGH FIRE BOILER MIN MAX BURNER DAMPER SETTING PUMP NOZZLE BT MODEL INPUT INPUT MODEL IN TOP BOTTOM DAMPER PRESSURE MAKE PSI 1 MPC4 1 3 16 5 16 Closed 2 5X90 B 3 5 X 80 4 5 X 90 6 0 X 90 6 5 X 80 PLP 7 0 X 80 PLP 8 5 X 80 PLP 9 5 X 70 PLP 10 5 X 70 PLP 11 0 X 80 PLP 12 0 X 80 PLP 14 0 X 80 BPS 16 0 X 80 BPS 15 0 X 80 BPS 16 0 X 80 BPS 5 7 3 8 1 4 1 4 MPC10 C2 OA 3 16 Both Wide Open 16 3 5 16 1 3 4 1 3 4 3 3 2 2 3 3 2 2 3 3 2 2 2 2 00 00 70 70 00 00 50 60 00 00 70 80 25 80 00 3 Table XIVb Power Flame Gas Burner Sp
47. 37104 3HV8 NOWIWOD SLHVd HlVd3H 79 80 5 N PER X Y Figure 56 MPC Common Bare Boiler Components continued 809009908 80809808 11619808 10 2 01 12720 60 1 7201 20 12720 10 2720 604609908 17709808 17909808 69519808 05909808 1090208 117692209 167692209 107692209 117692209 107692209 180692209 170692209 170692209 160692209 120692209 110692209 100692209 10 192101 80909808 10 092101 ON vor cl Sct Str o 91 4 vL vor v 21 24 SE vor v ELS ES ES Sb v 01 sb sb 60 80 70 90 60 0 EM 4 24 E SS lt
48. 38 Wrench well until water tight Locate L4006A Operating Control and remove knockout on casing closest to mounting hole Connect end of harness with forked terminals to casing knockout Connect wires to terminal on limit control wires are interchangeable Refer to Figure 39 Connect opposite end of L4006A Operating Control Harness to right side junction box cover hole location 1 as shown in Figure 40 Locate mating connectors labeled operating control inside right junction box Join mating connectors which are polarized and lock together Lightly tug on connectors to make sure they are secure If no other controls are being installed at this time secure Cover and Cover to jacket rear top panel with two 2 8 x 1 2 lg hex head SMS per cover Install 7 8 knockout plugs provided to all unused holes refer to Figure 40 Figure 39 Install Standard Trim and Operating Control Figure 40 Control Connections to Internal Wiring Harness 53 S Installing Optional Controls if applicable Install 7 8 knockout plugs provided to all 1 Install M amp M 750P MT 120 Probe Low Water Cut unused holes refer to Figure 40 Off LWCO 2 Install High Limit Control w Manual Reset a Apply thread sealant to 34 probe and install in LAO06E Tapping see Figure 38 Wrench hex until a Apply thread sealant to 3 4 immersion well water tight and install in Tapping F
49. 40 TCP w J 4077 TCP wid 40 TCP w H 40 TCP w H 40 TCP wid 13 Section oe Te Wi 27 TIP w J 3334 TCP 33 TCP w H 27 w J 3494 TCP w J 3494 TCP wid 33 94 TCP wid 33 TCP w H 14 Section 34 TCP w H 33 TIP w J 34 TCP w J Left 407 TCP wid 3394 TIP w J 3394 TCP w H E 33 w H 3394 w J 40V TCP w J 40V TCP wid 3394 TIP wid 407 TCP w H 16 Section 40 TCP w H 33 wid 407 TCP w J UEM 3256 TOP wid 33 TOP wh 2096 TOP wii 33 TOP wi 3334 TCP wid 3394 TIP wid 3394 TCP w H 3334 w H 3394 TIP wid 3334 wid Panel Designations TCP w J Top Corner Panel w Joiner Bracket Top Corner Panel w Holes TIP w J Top Intermediate Panel w Joiner Bracket Boiler Size 8 Section 15 Section 43 Step 5 12 thru 18 Section Boilers locate top Step 6 Repeat same procedure as Steps 1 thru 5 to intermediate panel s 3 per Table X and secure to install outer top panels to right side frame rails panel 1 and each other using two 2 8 x 12 lg hex head SMS per joint Align mounting holes in panel s 43 with holes in frame rails and secure with two 2 8 x 1 2 Ig hex head SMS per rail Locate top corner panel 2 per Table X and secure to last top intermediate panel 3 installed using two 2 8 x 1 2 10 hex head SMS Secure panel 2 to rear frame rails using two 2 8 x 1 2 I
50. 5 8 flat washer and 5 8 hex nut on each rod protruding through the front legs On 8 through 18 section block assemblies additional rods and couplings nuts are required to span the distance On these larger sizes thread couplings on front rods to mid point of coupling halfway pull next rod forward to meet front coupling Hold front coupling not front rod while threading rear rod into coupling nut until it contacts front rod at mid point Repeat this process until both lower rods protrude through rear section legs In the following order place a 5 8 flat washer 5 8 tension spring and 5 8 hex nut on both rods Hand tighten rear nut only to remove all slack from the lower rod assemblies Use a torque wrench adjusted for 20 ft Ib of torque to tighten four 4 rear hex nuts In lieu of a torque wrench use a combination wrench to tighten nuts approximately 34 turn beyond hand tight to set tension Excess length of draw up rods must not extend beyond front and rear section to ensure proper fit of jacket adjust accordingly Step s Release tension on Manual Draw up Assemblies and remove Now proceed to Step C of this Section on Page 24 Hydrostatic Test Table VI Proper Arrangement of Threaded Rods and Coupling Nuts Block Assembly Size Retention Rod Coupling Nut Arrangement Model Front 4 5 MPC6 MPC7 8 9 10 11 12 MPC13 MPC14 MPC15 MPC16 MPC17 MPC18 22 Block As
51. 80031 second Pass Fueway 88 1L T T TT Ty Baffle Cartons 28845 10184005 Stainless Stee args 10184048 Flueway Cartons 10184007 18409 10100 Third Pass Flueway Baffle Carton 101852 01 1 Cold Rolled Steel wmoa 101401 1 1 a 30 PSI Water Trim ss amp Control Cartons wroc 088531 bbb bp wmop __ woa 50 PSI Water Trim 10185302 30 PSI Water Trim amp Control Cartons wreos 10854221 FueOuetDamperCatn 7 _____ Foo wes FueOuetDamprCatn amp _____ 1 247302 _______ Damper Carton 10 10247308 ____ Flue Outlet Damper Canon 12 84 INSPECT SHIPMENT carefully for any signs of damage equipment is carefully manufactured inspected and packed Our responsibility ceases upon delivery of Boiler to carrier in good condition Any claims for damage or shortage in shipment m
52. ANNEL 2 8 X 2 1 2 HEX HEAD SHEET METAL SCREW CHASEWAY CHANNEL EXTENSION VERTICAL FRAME RAIL TYPICAL 42 Figure 24d Internal Wiring Harness Components Install Chaseway Channel Extension s 39 Install 1 13 16 Ig pieces on horizontal raw edges Note If Sage Boiler Control SBC is to be used at both ends of chaseway channel assembly Install with boiler refer to installation section of Sage 4 11 16 Ig pieces to vertical chaseway channel Boiler Control Instruction Manual located in flanges inside primary junction box as shown in Sage Boiler Control Parts Carton at this time Figure 24e Review installation section of SBC manual in its entirety and keep on hand during assembly of boiler Installation of SBC sensors and wiring is much easier when it is done in parallel with installation of MPC internal wiring harness and jacket panels 5 Locate and install internal control safety circuit wiring harness Start with harness end that has three 3 connectors insert connectors through rectangular opening on front and rear of primary junction box Pull harness through J box until second set of three 3 connectors can be inserted through front opening Pull on harness to remove slack in J box secure in J box Center connectors in primary J box and harness to end of chaseway channel using wire tie secure harness to chaseway using nylon wire tie No No 2 as shown in Figure 24f 1 see Figure 24f MAIN CHASEWAY C
53. Burner Rotary Cup Annually Refer to burner instructions Interlock Low Fire Start Interlock Annually Refer to burner instructions Automatic Fuel At least annually Service Technician Under supervision of gas utility Changeover Control Dual Fuel Safety Relief Valve As required Operator In accordance with procedure in Section VI ASME Boiler and Pressure Vessel Code Recommended Rules for Care and Operation of Heating Boilers Burner Components Semiannually Service Technician Refer to burner instructions Inspection SECTION VII BURNER SPECIFICATIONS boiler ratings and capacities based upon the following burners pump pressures nozzle sizes and manifold pressures Refer to instructions furnished with burner for additional information regarding proper installation fuel piping wiring details burner adjustments service instructions and burner start up Table Beckett 2 Oil Burner Specifications PUMP BURNER BURNER BURNER SETTINGS PRESSURE BOILER PSI NOZZLE MODEL MAKE LOW FIRE HIGH FIRE LOW HIGH AIR FIRE FIRE SHUTTER is sss cree s 2 W 15 Dean 275X70 8 30 55 cree croa o es 0 Delavan 5070 8 weer 40 e7 cree crexe s Delavan 500 45 8 zo 184 cree crea s s 40 200 Delavan 800x4576 100 crese s 25 a
54. ES W 4 RETURN amp SUPPLY TAPPINGS MANIFOLD Figure 15 Hand Form Support Channel Bracket AXIS OF 3 Tibe Neg 4 Locate horizontal support channels and FH 1 Hardware Bag s Position two 2 support channel brackets on floor and place horizontal support channel over brackets All three 3 holes in both parts must be in alignment if they are not rotate bracket Secure brackets to channel using four 4 8 x 1 2 hex head sheet metal screws see Figure 16 Repeat until all horizontal channels and brackets are assembled VERTICAL AXIS OF REAR SECT Figure 14 Orientation of Return Manifold NOTICE Orientation of return manifold is critical for proper alignment of return water mixing tube one 1 2 5 8 12 spacer two 2 washers one 1 hex nut on the opposite end of rod Repeat for second bracket refer to assembled end view Figure 17b 7 Mount front center horizontal channel pa x Mr nx assembly lies to appropriate casting s on block I SHEET METAL SCREW assembly as outlined in Table Position threaded rods on channel assemblies over slotted lugs on casting as shown in Figure 18a Spread inside washers until rod drops to bottom of slot as shown in Figure 18a Detail A Hand tighten nuts make sure washers engage casting below washer retaining lugs see Detail B Repeat for all remaining bracket attachment points IMPORTANT ALL 3 HOLES
55. HANNEL OR CHANNEL EXTENSION PROTECTIVE PROTECTIVE EDGE TRIM FC 211 SUPPLY MANIFOLD MAIN CHASEWAY gt gt CHANNEL ars PROTECTIVE EDGE TRIM FRONT FRAME RAIL PRIMARY JUNCTION BOX REAR FRAME 4 Figure 24e Internal Wiring Harness Components Install Protective Edging P s WIRE TIE 4 THRU 15 AS REQ D TO END OF CHASEWAY CHANNEL S WIRE TIE lt WIRE TIE 1 WIRE TIE 2 e FRONT FRAME RAIL PROTECTIVE SLEEVE ON HARNESS INTERNAL WIRING HARNESS REAR FRAME RAIL L Figure 24f Internal Wiring Harness Components Install and Secure Harness to Chaseway 40 Insert first set of harness connectors through Table IX Internal Harness Adjustment opening in rear of secondary junction box Remove Harness Hamess Adjustment 00000 excess slack between J boxes until protective sleeve Boiler is centered on raw edge of channel extension secure Tie harness to channel using nylon wire tie No 3 see Figure 24f Use remaining nylon cable ties to secure harness to chaseway channel at every set of holes start at T wire tie No 4 and working forward removing slack 78edon at each juncture When securing harness do not IR allow contact with side
56. INSTALLATION OPERATING AND SERVICE INSTRUCTIONS FOR Model MPC MULTI PASS COMMERCIAL CAST IRON BOILER Du tiste Intertek 3050579 For service or repairs to boiler call your heating contractor When seeking information on boiler provide Boiler Model Number and Serial Number as shown on Rating Label Boiler Model Number Boiler Serial Number Installation Date Heating Contractor Type of Fuel Address Phone Number www burnhamcommercialcastiron com 101786 01R5 11 10 Price 5 00 EQUIPMENT CHECK LIST NOTE Only factory packaged and firetested units are eligible to bear the UL listing mark This Equipment Check List has been provided so that PART NUMBER the Installer can determine if all parts have been provided 7 for the boiler ordered It covers standard equipment for 101831 05 Uri of Measure EA Knockdown boilers 4 thru 18 section models Optional 61756 5 oR 2 2 equipment ordered will be in addition to or in lieu of LABEL equipment shown below To simplify boiler assembly instructions refer to carton MPO DESIGNATION 4 5 E 4 MULTI BOILER BACA BOX designations located in box on Bar Code Labels see Figure ASSEMBLY CARTON MPG 1 When instructed locate and open specified carton MPC MULTI Some cartons use all contents immediately and others use parts throug
57. L vl EL OL 60 80 20 90 SO ON ON Hed uonduoseq Ayuend suonoes A18W3SSV NOILO3S 1579 77 78 ec 52 SC TE DARKS S Ces ip X PYG PPR M M M SM OMS WA A C 2 SN S SN Y Y YS Figure 56 MPC Common Bare Boiler Components 815000908 1 Lb b LE b b LE E peie d deo 7061 2809208 GE UE DU ED UE TT 35219 14015 061 809208 8 41 Z 885 4 X 409 12589 1eqi4 ssejo 14615 gel 1010009908 1 1 LE L L b LE E L ejddiN 21 2 1 2 X LAN Z JU9UOdWOD 1104 uoneAjesqO 0 8 19101 194se5 uoneuesqo 8I 10 169001 50 201011 Bus 2 L0 Zv9201 Ll LE BL EL d Bums 9 10 889001 pep cp 2 2 91 LO 6SZLOL 01 OL OL OL OL OL OL OL OL OL OL OF OF OL OI peye 61 2 1 1 1 90 4 61 10 89 101 01 OL OL OL OL OL OL OL OL OL OL OF OF OL OI JeuseM 207
58. LASS ROPE AND SEALANT to the grooved joints between 21 adjacent sections as the boiler operates with a positive pressure in the firebox and products of combustion will escape between sections unless they are properly sealed The rope and sealant should be applied before each section is placed on the assembly As assembled length increases use 3 4 coupling nuts and additional rods provided in Kit to extend draw up rod length Step CONTINUE ASSEMBLING SECTIONS IN THEIR RESPECTIVE ORDER until the block assembly is complete Be certain that all sections are drawn up iron to iron at both nipple ports DO NOT REMOVE the draw up tool leave it under tension until the retention rods are in place Step r Locate the threaded 5 8 retention rods washers tension springs and nuts supplied in Boiler Assembly Carton marked Assemble both top retention rod assemblies as shown in Figure 5 Detail B using the proper arrangement per Table VI The tension spring should always be located at the rear of the boiler These rod assemblies can be lowered directly into slotted lugs on each side of the upper nipple port Hand tighten the rear nuts only do not torque nut at this time casting legs have two 2 holes Slide the lower retention rods through the upper hole in eachleg Start at the front or rear which ever is easiest per the arrangement shown in Table VI With the rods in place install a
59. MUST BE ALIGNED 2 SUPPORT CHANNEL _ BRACKET 8 Mount rear horizontal channel assembly to rear section and adjacent center section as shown in Figure 18b Position assembly behind supply manifold spread washers and lower threaded rod Figure 16 Secure Brackets to Horizontal Channel into slotted openings on both castings as shown in Figure 18b Detail A Hand tighten nuts make sure washers engage casting below washer retaining lugs as shown in Detail B Repeat for opposite side 5 Add front center section mounting hardware to all but one 1 horizontal support channel assembly Lay channel assembly on floor with brackets facing up see Figure 17a Install hardware as shown with two 2 washers and two 2 1 2 12 spacers 9 Wrench tighten hex nuts on all channel assemblies making sure rods are fully seated in slotted between bracket legs and one 1 washer and one 1 openings hex nut on each end of 3 8 16 x 3 1 4 lg rod see 10 Locate and install lower front center section assembled end view in Figure 17a Repeat for all brackets to casting legs Brackets are universal and brackets can be used on either side of block assembly Refer to Table VIII for appropriate casting leg to be used for bracket attachment Brackets mount to rear surface of leg with offset toward the rear as shown in Figure 19 Hold bracket at a 45 angle while 6 Addrear section mounting hardware to remaining horizontal support channel assemb
60. Manifold or C aligned with front of boiler when water tight 52 Note Supply manifold must be installed with 1 couplings aligned with front and rear axis of boiler Apply thread sealant and install temperature pressure gauge into tapping see Figures 38 and 39 Wrench until water tight Tighten gauge using hex on stem do not tighten or apply pressure to case Apply thread sealant and install relief valve and pipe fittings in Tapping see Figure 38 Fittings should be arranged as shown in Figure 39 By code relief valve must be installed vertically Based on vent pipe arrangement and access relief valve can be installed with discharge facing a left or right RELIEF VALVE DI 90 STREET S 29 NIPPLE OPERATING CONTROL HARNESS 14006 OPERATING i CONTROL IMMERSION BUSHING WELL TERI RESSURE SUPPLY MANIFOLD GAUGE y REAR OF BOILER FRONT OF BOILER 77 SNAP IN HOLE PLUG COVER PLATE B _ SUPPLY MANIFOLD 25 8 X HEX HEAD SMS COVER PLATE A 8r Y 4 Le 3 rm 0 J 17 y 1 n 2 ze q B m INTERNAL J DS WIRING HARNESS 5 5 L Apply thread sealant to 3 4 immersion well and install in tapping D as shown in Figure
61. Manual 54 Fire Hold CORTON 54 Low High Low Control or Modulating Control eerie 55 Install Flue Outlet Damper Assembly 56 Install Optional Burner Swing Door Cover Split Jacket Panels 57 SECTION IV INSTALLATION INSTRUCTIONS Packaged Boiler Shipping Information eee nennen nnn nennt 58 Boiler Piping Heating nnne nnn nnne 58 Boiler Piping Domestic Hot nennen nnn nnn nnn nnne nnn nnn 64 Relief Valve Piping 64 Electric Wirth dete 64 SECTION V OPERATING INSTRUCTIONS FUMING 65 Adjusting Controls 65 POTE cnl 65 T St 5 55 5 2 5222 2222 225 22216222 66 Initial Cleaning Water 66 Frequent Water 22 67 67 TABLE CONTENTS continued SECTION VI SERVICE INSTRUCTIONS Cleaning Boiler Heating
62. Mounting Hardware Rear Section Horizontal Channel Assembly w Mounting Hardware Mount Rear Section Horizontal Channel to Block Assembly Mount Rear Section Horizontal Channel to Block Assembly Attachment of Lower Front Center Section Bracket to Casting Leg Attachment of Lower Rear Section Bracket to Casting Leg Securing Frame Side Channels to Horizontal Top Channel and Lower Brackets Lower tie Bar Installation Heat Exchanger Insulation One Piece and Modular Wrappers Internal Wiring Harness Components Internal Wiring Harness Components Mounting Junction Boxes Internal Wiring Harness Components Install Main Chaseway Channel Internal Wiring Harness Components Install Chaseway Channel Extension s Internal Wiring Harness Components Install Protective Edging Internal Wiring Harness Components Install and Secure Harness to Chaseway Internal Wiring Harness Components Secure Harness to Vertical Channel Figure Number Appendix A Figures continued Page Number Description Section Ill Boiler Assembly Instructions Knockdown Boiler continued Internal Wiring Harness Length Adjustment for Penetration Through Side of Jacket Front Panel Install Top Corner Intermediate Panels Install Jacket Front Panel Jacket Split Rear Panel Detail Install Jacket Split Rear Panel Installing Jacket Top Panels Viewed From Front Install Jacket Top Panels Viewed From Rear Install Jacket Rear Top Panel Viewed Front Re
63. ONS Knockdown Boiler Install Common Parts to Block Hinge Hardware Flue Collector Clean out Covers Etc 25 Install Supply and Return Manifolds meee 27 Install Return Water Mixing Tube 27 Install Jacket Support Frame to 30 Install Heat Exchanger Insulation 37 Install Internal Wiring Harness Components 38 Install Jacket Top Corner Panels ee 43 Install Jacket Front and Rear Panels 44 Install Jacket Top and Side Panels 45 Install Burner Swing Door BSD 4 0 47 Install 2 and 34 Pass Flueway 4 4 49 Procedure to Close and Secure Burner Swing Door ennt 50 Install Burner Adapter Plate and Mount Burner Burner Specific 50 Connecting Internal Wiring Harness to Burner Controls esee 51 Install Standard Water Trim and 52 Install Optional Controls PODS LWCO ED 54 High Limit Control w
64. W HIGHILOW 3 4 E 7 SUPPLY MANIFOLD CONTROL IMMERSION WELL REAR OF BOILER PA FRONT OF gt BOILER Figure 44 Install Low High Low Control Connect wires to terminals as follows B Terminal Black Wire w White Tracer W Terminal Gray Wire R Terminal Red Wire w White Tracer iii Install Remote Sensing Bulb into control well and secure with retaining clip Coil excess sensor tubing as shown in Figure 45 iv Mount T991A Control to rear panel on left side of return manifold with two 2 self drilling 8 x 1 2 lg hex head SMS provided as shown in Figure 45 SUPPLY MANIFOLD MODULATING CONTROL HARNESS 3 4 IMMERSION WELL CAPILLARY TUBE amp BULB a CN T994A Ne j RETURN MANIFOLD MODULATING CONTROL 5 Figure 45 Install Modulation Control 55 v Connect opposite end of T991A Modulating Control harness to right side junction box cover hole location 4 as shown in Figure 40 vi Locate mating connector labeled LO HI LO MOD inside right junction box see Figure 40 Join mating connectors which are polarized and lock together Lightly tug on connectors to make sure they are secure vii If no other controls are being installed at this time secure Cover A and Cover to jacket rear top panel with two 2 8 x 1 2 1g hex head SMS per cover Install 7 8 knockout plugs provided to all unused holes refer to Figure 40 Install Flue Outlet D
65. Y BAFFLE INSTALLED SEE DETAIL A Figure 33 Install 274 Pass Flueway Baffles 49 Close Burner Swing Door and secure using 4 5 8 flat washers 4 9 16 lock washers and 4 9 16 12 x 2 lg cap screws as shown in Figure 34 There are 4 points of internal contact around perimeter of BSD and Front Section These stop the door travel when tightening hardware to prevent excess compression excessive torque Never tighten hardware on either side 100 without using the alternating tightening method Failure to follow the prescribed procedure could cause thread damage a crack in the casting or a leak in the door seal of rope gasket Therefore continued tightening of O Mount Burner Adapter Plate to Burner Swing Door hardware will only bend the hinge pockets Use a hand wrench to tighten the hardware Use an alternating Also refer to Burner Installation Manual for mounting tightening method from right side to left side cap instructions specific to each burner provided with screws to secure door until sealed without applying burner JACKET FRONT p FRONT SECTION ZU PANEL JACKET FRONT PANEL 5 8 FLAT WASHER WASHER 9 16 12 X 2 LG CAP SCREW ROPE PIN SIDE UP a INSULATION HINGE LOOP O 2 5 8 FLAT WASHER 9 16 SPLIT LOCK WASHER 9Me2X216 CAP SCREW DETAIL
66. a pressure plate on the opposite end of threaded rod in upper nipple port Place remaining 61 2 dia pressure plate on rod protruding through lower nipple port NOTICE As assembled length increases use 3 4 coupling nuts and additional rods provided in Kit to extend draw up rod length Slide 34 washer hydraulic ram and second 34 washer over each rod assembly Remove all slack from assemblies and apply draw up rod clamps Center upper pressure plates on nipple port and boss while pumping ram set until tension holds assembly in place Repeat for lower assembly Refer to Figure 5 to verify proper arrangement CAUTION Rods should be approximately centered openings so that rods and couplings when used do not drag on pipe thread in end section tappings WARNING READ THE STATEMENTS BELOW BEFORE ATTEMPTING TO USE HYDRAULIC EQUIPMENT Release pressure in ram pumps before attempting to remove clamps Do not stand in line with draw up rods at either end when hydraulic pressure is being applied As a safety measure ends of draw up rods should be covered while sections are being drawn in case rods should snap while under tension Do not operate ram against draw up coupling Do not operate pump after ram has reached stroke limit Step d Draw up Sections Use hydraulic rams to draw up sections by applying pressure alternately on the draw up rods When rams reach stroke limit release press
67. al rails with two 2 8 hex head sheet metal screws as shown in Figure 24g clamp must be facing inward to prevent interference with jacket 7 Adjust length of internal wiring harness to match boiler size see Table IX and Figure 25 for details JACKET FRONT PANEL 2 SEE DETAIL A sl 4 thru 8 section boilers are shipped with the internal harness length suitable for an 8 section boiler To modify harness for a 7 section cut nylon wire tie A for 6 section cut amp B for 5 section cut A B amp C and for a 4 section cut A B C amp D Refer to Table IX and Figure 25 9 thru 13 section boilers are shipped with the proper harness length suitable for a 13 section boiler For boiler sizes 9 thru 12 modify harness per Table IX also refer to Figure 25 14 thru 18 section boilers are shipped with the proper harness length suitable for an 18 section boiler For boiler sizes 14 thru 17 modify harness per Table IX also refer to Figure 25 14 WIRE BUNDLE CABLE CLAMP VENDOR TAPE NYLON WIRE TIE VENDOR TAPE 7 WIRE BUNDLE DETAIL A Figure 25 Internal Wiring Harness Length Adjustment for Penetration Through Side of Jacket Front Panel 42 Locate Jacket Corner Panels packed in carton Step 3 Secure top corner panel 1 to next set of frame marked JC 2 Install Jacket Top Corner Panels per rails wi
68. all High Limit Control junction box Join mating connectors which c Connect opposite end of L4006E High Limit are polarized and lock together Lightly tug on Control harness to left side junction box cover connectors to make sure they are secure B hole location 5 as shown in Figure 40 g Proceed to next control option listed below for d installation details If no other controls are being installed at this time secure cover A and cover B to jacket rear top panel with two 2 8 x 1 2 1g hex head SMS per cover Locate mating connector labeled Limit inside left junction box Join mating connectors which are polarized and lock together Lightly tug on connectors to make sure they are secure e Proceed to next appropriate control option SUPPLY MANIFOLD listed below for installation details If no other controls are being installed at this time secure Cover A and Cover to jacket rear top panel with two 2 8 x 1 2 1g hex head SMS per cover Install 7 8 knockout plugs provided to all unused holes refer to Figure 40 3 Install Low Fire Hold Control L4006B M amp MUWCO way 750P PROBE LWCO a Apply thread sealant to 1 2 immersion well REAR OF qe LOCK WASHER BOILER XS amp WING NUT and install in Tapping J as shown in Figure 38 Wrench well until water tight y b Locate LA006B Low Fire Hold control and
69. ally supplied with the boiler and burner ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER FILL HEATING SYSTEM WITH WATER 1 CLEAN HEATING SYSTEM IF boiler water is dirty Refer to step F for proper cleaning instructions for water boilers Fill entire Heating System with water and vent air from system Use the following procedure on a Series Loop or Multi zoned System to remove air from system when filling a Close isolation valve in boiler supply piping b Isolate all circuits by closing zone valves or balancing valves c Attach a hose to hose bib located just below isolation valve in boiler supply piping Note Terminate hose in five gallon bucket at a suitable floor drain or outdoor area d Starting with one circuit open zone valve e Open hose bib f Open fill valve Make up water line should be located directly above isolation valve in boiler supply piping g Allow water to overflow from bucket until discharge from hose is bubble free for 30 seconds h Open zone valve to the second zone to be purged then close the first Repeat this step until all zones have been purged but always have one zone open At completion open all zone valves 1 Close hose bib continue filling the system until the pressure gauge registers normal system design operating pressure Close fill valve Note If make up water line is equipped with pressure reducing valve system will automatically fill to normal syst
70. amper Assembly see Figure 46 1 Locate flue outlet damper carton as applicable see Table below Open carton remove a flue outlet damper assembly a flue outlet damper gasket and mounting hardware bag 12 pcs each 5 16 18 x 7 8 hex head plated cap screws and 1 4 USS plated washers Assemble two cap screw washer combinations then insert cap screws washers through a flue outlet damper assembly mounting ring at 3 o clock and 9 o clock positions Place the flue outlet damper gasket onto cap screws and position damper with gasket onto boiler rear flue collector aligning screws with flue collector threaded holes Thread the screws at 3 o clock and 9 o clock positions into flue collector threaded holes hand tight Assemble remaining cap screw washer combinations then insert cap screws washers through a flue outlet damper assembly mounting ring gasket and thread the screws into flue collector threaded holes hand tight Alternately tighten the screws with an open end or socket head wrench to complete the assembly Boiler Model Flue Outlet Damper Flue Outlet Recommended Vent Carton Part Number E Diameter Sue _ Size 4 amp MPC5 102473 01 7 ___7 7 7 Dia MPC6 thru MPC8 102473 02 thru 12 102473 03 13 thru MPC18 102473 04 RETURN MANIFOLD DAMPER GASKET DAMPER FLANGE 5 18 X HEX HEAD CAP SCREW AND 1 USS FLAT WASHERS 12 REQ D
71. an the distance On these larger sizes thread couplings on front rods to mid point of coupling halfway pull next rod forward to meet front coupling Hold front coupling not front rod while threading rear rod into coupling nut until it contacts front rod at mid point Repeat this process until both lower rods protrude through rear section legs In the following order place a 5 8 flat washer 5 8 tension spring and 5 8 hex nut on both rods Hand tighten rear nut only to remove all slack from the lower rod assemblies Use a torque wrench adjusted for 20 ft lb of torque to tighten four 4 rear hex nuts In lieu of a torque wrench use a combination wrench to tighten nuts approximately 34 turn beyond hand tight to set tension Excess length of draw up rods must not extend beyond front and rear section to ensure proper fit of jacket adjust accordingly Step h Release tension on hydraulic pumps and rams and remove C HYDROSTATIC TEST After the boiler sections have been assembled it is essential that the boiler be hydrostatically tested before the jacket frame insulation internal wiring piping or jacket is installed THIS TEST IS AN ASME CODE REQUIREMENT 1 Block Assembly must be free of air provide valve in 4 bushing on top supply tapping to purge air during the filling process Plug all boiler tappings and fill entirely with cold water CAUTION DO NOT install gauge until after hydrostatic testing the
72. and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency This boiler is supplied with controls which may cause the boiler to shut down and not re start without service If damage due to frozen pipes is a possibility the heating system should not be left unattended in cold weather or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative This boiler is designed to burn No 2 fuel oil only Do not use gasoline crankcase drainings or any oil containing gasoline Never burn garbage or paper in this boiler Do not convert to any solid fuel i e wood coal Do not convert to any gaseous fuel i e natural gas LP All flammable debris rags paper wood scraps etc should be kept clear of the boiler at all times Keep the boiler area clean and free of fire hazards Always keep the oil supply valve shut off if the burner is shut down for an extended period of time Probe and float type low water cutoff devices require annual inspection and maintenance Refer to instructions in Section VI Paragraph C for inspection and cleaning instructions Model cast iron boilers are d
73. ar Install Burner Swing Door Install 3rd Pass Flueway Baffles 4 thru 11 Section Boilers Only Install 2nd Pass Flueway Baffles Secure Burner Swing Door for Tight Perimeter Seal Install Burner Adapter Plate and Burner to Burner Swing Door Burner Adapter Plate Options Install Jacket Front Panel Harness Cover Plates and Logo Plate Purpose of tappings in Supply Manifold Install Standard Trim and Operating Control Control Connections to Internal Wiring Harness Install Probe Low Water Cut Off Install High Limit Control Install Modulation Control Install Low High Low Control Install Modulation Control Install Flue Outlet Damper Assembly Install Jacket Panels for Optional Burner Swing Door Cover Packaged Boiler Shipping Information Recommended MPC Minimum Piping Single Boiler Application Recommended MPC Minimum Piping Multiple Boiler Application Alternate MPC Minimum Piping Single Boiler Application Alternate MPC Minimum Piping Multiple Boiler Application Parallel Piping Conversion Typical Burnham Boiler Primary Secondary Loop System Recommended Piping for Combination Heating amp Cooling Refrigeration Systems Figure 25 42 Figure 26 44 Figure 27 44 Figure 28 45 Figure 29 45 Figure 30a 46 Figure 30b 47 Figure 30c 47 Figure 31 47 Figure 32 49 Figure 33 49 Figure 34 50 Figure 35 50 Figure 36 51 Figure 37 52 Figure 38 52 Figure 39 53 Figure 40 53 Figure 41 54 Figure 42 54 Figure 43 55 Figure 44 55 Figure
74. ately 10 2 as part of the installation CO2 gas or 13 2 CO2 oil with an overfire pressure as listed in Table II of this manual Final 1 HOT WATER HEATING This boiler must be adjustments should be made once the unit is installed in strict accordance to the instructions installed found in this installation manual Deviations from these installation instructions may void B BOILER PIPING HEATING APPLICATIONS manufacturer s warranty HEATING SYSTEM see Figures 49a 49b 50a and 50b Number of Length Width Height Center of Shipping Sections Gravity D Weight Lbs 5 15 01 von 4 597 comi 122422 5 ame em co v ws em sm e we aee e con Width can vary with gas train configuration Varies slightly with burner and gas train configuration 6 6 6 4 5 7 10 11 12 13 14 15 16 17 18 1 not tilt Exercise caution when lifting to avoid damage 2 This boiler can be lifted by fork truck Do not truck from front 3 When lifting from rear forks must extend from beyond center of gravity and second skid cross bar 4 When lifting from side forks must extend to opposite skid rail and straddle center of gravity 5 Cablespreader is to prevent jacket damage Spreader width should equal B width of skid 1
75. ation Code for Oil Burning Equipment for recommended Installation Practices B The equipment shall be installed in accordance with the current Installation Code for Gas Burning Appliances and Equipment CSA B149 and applicable Provincial Regulations for the class which should be carefully followed in all cases Authorities having jurisdiction should be consulted before installations are made C wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and or Local Regulations DANGER Indicates an imminently hazardous situation which if not avoided will result in death serious injury or substantial property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death serious injury or substantial property damage CAUTION Indicates a potentially hazardous situation which if not avoided may result in moderate or minor injury or property damage NOTICE Indicates special instructions on installation operation or maintenance which are important but not related to personal injury hazards This boiler has a limited warranty of which is printed on the back of this manual It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is complete The warranty for this boiler is valid only if the boiler has been
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77. boiler Gauge failure may result 2 Assembled boilers shall be subjected to a hydrostatic test of not less than 1 times the maximum allowable working pressure as established by the relief valve supplied with the boiler For example a boiler with a 50 psi relief valve must be subjected to a test pressure of 75 psig to 85 psig WARNING Failure to properly hydrotest all boilers at the correct pressure may result in section assembly failure in operation 3 EXAMINE BOILER CAREFULLY INSIDE AND OUTSIDE to insure against leaks from cocked nipples or through concealed breakage caused in shipping and handling This precaution is for your protection and will simplify handling of necessary replacements and adjustment claims 4 After making certain that there are no leaks drain boiler and remove plugs from boiler trim and other connections 439599 3904 301937705 301937109 3013 1914 91 6 v M3NOS dvd 91 8 X 81 91 4 98 1 19 139599 N3dWva 197470 30114 M3HSVM 1914 49 1 MGNOS e 91 8 X 81 91 5 21 1404 9NISN3S IYNSSIYd 07 548 ldN v l AlgW3SSV s3dAvG 141110 3014 M3HSVM 1913 9 M3NOS dvo 1 x 91 8 9 1394 dlddlN 291 8 X 1 uv jquiessy x20 g 01 54
78. burnhamcommercialcastiron com within ten days after the installation of the boiler although failure to comply with this request will not void the owner s rights under these warranties Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties the owner should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the owner should write to Burnham Commercial P O Box 3939 Lancaster PA 17604 giving full particulars in support of the claim The owner is required to make available for inspection by Burnham Commercial or its representative the parts claimed to be defective and if requested by Burnham Commercial to ship these parts prepaid to Burnham Commercial at the above address for inspection or repair In addition the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE BURNHAM Burnham Commercial P O Box 3939 Lancaster PA 17604 Revised November 1 2009
79. c Hot Water DHW In some applications depending on the control strategy outdoor reset setpoint operation etc and size of the boiler it is recommended to isolate the space heating load from the DHW load For example if the domestic load is more than the space heating load it is beneficial to dedicate one or more boilers solely to DHW production and one or more boilers solely to space heating since during mild weather conditions the boiler s will have more capacity than is required Piped in the recommended manner the space heating boiler s can be shut down during the summer months to conserve energy and to avoid short cycling The use of indirect water heaters for domestic hot water generation is commonly recommended since they provide DHW storage A tempering valve and recirculation loop are advantageous in these applications because they provide both high temperature and tempered domestic water to the RELIEF VALVE SUPPLY MANIFOLD system eliminating the need to purge and waste water until it reaches the desired temperature See Figures 49a 49b 50a and 50b for recommended indirect water heater piping NOTICE DO NOT use the boiler circulator as an indirect domestic hot water system circulator D RELIEF VALVE DISCHARGE PIPING see Figure 54 Pipe discharge to within 4 of floor or to a suitable drain Do not reduce piping size or install shut off valve in disc
80. ckaged and firetested units are eligible to bear the UL listing mark A FACTORY ASSEMBLED SECTIONS The outlined in Section I Lifting arrangement and weights assemblage should be set in the proper location as are given in Figures 4a and 4b FOUR LEG LUFTING SLING W 5 8 DIA HOOKS n RATED CAPACITY SHOULD Number of Lifting Lift Locations EXCEED LIFTING WEIGHT BY Weight 25 SEE CHART Sections Hooke Hooks 48 MAXIMUM SPAN BETWEEN 7 CASTING LUGS SEE CHART Rear Section 9 Section 10 BLOCK ASSEMBLY Figure 4a Lifting Instructions Limited to 4 thru 12 Section Block Assembly No Steel Base Optional Steel Shipping Base 4 thru 12 Section Block CABLE SPREADE SE NOTE 5 Number of Mid oe Center of Shipping Sections Inch Inch Gravity Weight D Inch Lbs 9 s en ams 14 5360 Standard Steel Shipping Base 13 thru 18 Section Block Number of Center of Shipping Sections Gravity Weight D Inch FORK TRUC d 1 not Tilt Exercise caution when lifting to avoid damage 17 18 2 This boiler can be lifted by fork truck Do not truck from front 3 When lifting from rear forks must extend from beyond center of gravity and second skid cross bar 4 When lifting from side forks must extend to opposite skid rail and straddl
81. defects in material and workmanship under normal usage for the time period specified in the chart below to the original owner at the original place of installation If a claim is made under this warranty during the No Charge period from the date of original installation Burnham Commercial will at its option repair or replace the heat exchanger not including labor If a claim is made under this warranty after the expiration of the No Charge period from the date of original installation Burnham Commercial will at its option and upon payment of the pro rated service charge set forth below repair or replace the heat exchanger The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows 1 121 314 5 6 7 81 9 10 No Charge Carbon Steel Charge Stainless Steel No Charge 20 40 60 80 100 NOTE If the heat exchanger involved is no longer available due to product obsolescence or redesign the value used to establish the retail price will be the published price as set forth in Burnham Commercial Repair Parts Pricing where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger whichever is greater ADDITIONAL TERMS AND CONDITIONS 1 Applicability The
82. diately WARNING Do not attempt to start the burner when excess oil or gas has accumulated in the combustion chamber when the unit is full of vapor or when the combustion chamber is very hot 65 TEST CONTROLS WARNING Before installation of the boiler is considered complete the operation of the boiler controls should be checked particularly the low water cutoff and the high limit control WARNING Chemicals used in treating boiler water are toxic and or harmful Always use protective clothing and equipment when working with near chemicals Contact local authorities to determine if treated boiler water can be discharged into local waste water system OPERATING 1 Filling of Boiler and System General In hot Raise and lower operating control setting as required to start and stop burner CHECK OPERATION OF HIGH LIMIT CONTROL Jumper operating control terminals Allow burner to operate until shutdown by limit Installation is not considered complete until this check has been made REMOVE JUMPER CHECK LOW WATER CUTOFF CONTROL Raise operating control setting to allow burner to operate Close isolation valves in supply and return near boiler piping Open boiler drain to allow water level to drop until burner operation is shut down by low water cutoff If necessary open relief valve for air to facilitate draining Close boiler drain and refill boiler Burner sh
83. ding the radiation Allow boiler water to reach operating temperature if possible 1 Continue to circulate the water for a few hours Stop firing the boiler c k Drain the system in a manner and to a location that hot water can be discharged with safety 1 Remove plugs from all available returns and wash the water side of the boiler as thoroughly as possible using a high pressure water stream m Refill the system with fresh water Add appropriate boiler water treatment compounds as recommended by your local qualified water treatment company Make pH or Alkalinity Test After boiler and system have been cleaned and refilled as previously described test the pH of the water in the system This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper except it gives specific readings A color chart on the side of the small hydrion dispenser gives the reading in pH Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 H OXYGEN CORROSION Add some appropriate water treatment chemicals 1f necessary to bring the pH within the specified WARNING range With this lower level of protection care must be exercised to eliminate all of the free oxygen in the system Oxygen contamination of the boiler water
84. e center of gravity 5 Cablespreader is to prevent casting damage Spreader width should equal B width of skid 12 Adjust cable lengths to lift at approximate center of gravity per chart Figure 4b Lifting Instructions 4 thru 18 Section Block Assembly w Steel Base 17 Then proceed to Step C of this section on Page 24 4 longer than required Use a permanent black HYDROSTATIC TEST marker to mark the rope approximately 1 8 FIELD ASSEMBLED SECTIONS If the boiler was DEVO pott eee pi d TUE ordered knockdown to be field assembled follow the SCISSOES Or ulity Knie block Apply a generous bead of red sealant to assembly procedure outlined on the following pages both ends of cut rope push ends together and 1 ASSEMBLY OF SECTIONS MANUAL DRAW smooth excess sealant over joint with your finger 18 UP These sections are designed to be drawn together one section at a time using the Manual Draw up Kit Burnham P N 102008 01 or P N 102008 02 using ordinary hand tools Tools required 1 34 Drive Ratchet 1 14 Socket 1 114 Combination or Open End Wrench 1 Can Thread Cutting Oil or Grease WHEN ASSEMBLING SECTIONS WITHOUT HYDRAULIC DRAW UP EQUIPMENT IT IS RECOMMENDED THAT ONE SECTION BE ASSEMBLED AT A TIME NEVER ASSEMBLE MORE THAN TWO SECTIONS AT A TIME Assembly Procedure refer to Figure 5 for Exploded View of Block Assembly and Draw up Hardware Step a
85. e passes Usea wire or fiber bristle brush to clean all of the surfaces of the combustion chamber and turnaround passages to the second flue passes Vacuum all loose debris in the bottom of the combustion chamber and in the turnaround passages to the second flue passes Remove the flue collector clean out covers at the rear of the boiler by removing four 4 5 16 cap screws and washers Through these clean out openings vacuum all loose debris from the bottom of the flue collector 3 REASSEMBLE BOILER a Reattach the flue collector clean out covers to the rear of the boiler verifying that the silicone coated rope gaskets are still in satisfactory condition Replace the rope gaskets if necessary before reassembly Tighten the covers snugly into place using original 5 16 hardware Do not over tighten Insert the flue baffles into the appropriate flue passes Inspect the insulation and silicone coated rope gasket on the inside of the BSD making sure that everything is in place and undamaged If the BSD insulation or rope gasket is damaged replace them Carefully close the BSD and secure it in place using the original 9 16 hardware When tightening the bolts make sure that the BSD is drawn in equally at all four corners Use an alternating tightening method from corner to corner to pull the door tight equally around the perimeter CAUTION Do not start the burner unless BSD smokepipe fl
86. ecifications BURNER BURNER DIFFUSER APPROX HIGH FIRE APPROX NAT GAS MINIMUM BURNER Opening DAMPER SETTING MANIFOLD PRESS NAT GAS MODEL IN TOP BOTTOM DAMPER ATORIFICETEE INLET PRESS i IN WC WC 4 500 JR15A 10 N A 1 2 MPC5 773 JR30A 12 N A 3 4 MPC6 995 JR30A 12 N A 13 16 MPC7 1216 JR30A 12 N A 1 3 32 MPC8 650 1438 JR50A 15 N A 3 4 MPC9 650 1660 JR50A 15 N A Wide Open MPC10 650 1881 JR50A 15 N A MPC11 650 2103 JR50A 15 N A MPC4 300 500 C1 G 10 3 16 5 16 Closed MPC5 300 773 C1 G 10 3 8 1 Closed MPC6 300 995 C1 G 12 1 4 1 3 32 1 3 8 C1 G 12 1 4 3 4 3 4 C2 G 15 1 4 1 Closed C2 G 15 1 4 13 16 11 16 C2 G 20A 3 16 Both Wide Open C2 G 20A 3 8 1 3 8 1 1 4 C2 G 20A 3 8 1 3 4 1 3 4 C2 G 20B 3 8 1 1 2 1 1 4 C2 G 20B 1 2 1 1 4 1 1 4 C3 G 20 1 2 1 7 8 Closed C3 G 20 5 16 1 3 4 1 3 4 17 3435 C3 G 20 3 8 2 2 MPC18 3657 C3 G 20 3 8 Both Wide Open ON JR BURNERS THIS DIMENSION IS THE GAP BETWEEN THE TWO DAMPER BLADES MINIMUM INLET PRESSURE FOR STANDARD UL GAS TRAINS ONLY CONSULT FACTORY FOR ADDITIONAL INFORMATION BOILER MODEL NII olalolni o 2 3 8 ALO gt MPC7 300 1216 MPC8 750 MPC9 750 1660 MPC10 750 1881 MPC11 750 2103 MPC12 750 2325 MPC13 750 2547 MPC14 750 2769 MPC15 2991 MPC16 3213 1438 5 16 2l
87. em design operating pressure Leave globe valve open j Open isolation valve in boiler supply piping k Remove hose from hose bib DANGER Do not operate boiler with pressure above maximum allowable working pressure listed on the Boiler s ASME Data Label DO NOT draw water from boiler while in use When adding water while boiler is in operation do not open supply valve fully but add water slowly C SET CONTROLS with burner service switch turned OFF 1 PRESS RESET BUTTON on primary control and release 2 BOILER OPERATING AQUASTAT The operating aquastat L4006A should be set to the designed supply temperature typically 180 F 3 BOILER HIGH LIMIT AQUASTAT The high limit aquastat LA006E can be identified with a red manual reset button Ideally the high limit aquastat should be set high enough above the operating aquastat setting so as to avoid nuisance shutdowns on manual reset The temperature must be set below the maximum permissible temperature for any system related component affected by boiler supply water Under no circumstances can the high limit aquastat be set higher than 250 D ADJUST BURNER according to the Burner Manual The MPC boiler controls operate the burner automatically If for unknown reasons the burner ceases to fire and the reset button on the primary control is tripped the burner has experienced ignition failure Before pressing the reset button call your serviceman imme
88. er Operating Requirements 134 8 7 Diaphragm expansion tank shown but 1441 other types of air elimination systems may be used 10 3 269 5 Figure 50a Alternate MPC Minimum Piping Single Boiler Application 9 6 3 0 7 1 5 2 2 2 4 4 4 4 4 4 EN 61 806 94181 0 59100 juej rodui 19430 pue sdoap 59715 odid 104 NOLIVNIWIT3 JO YO xt NOISNvdX3 Adans 31545 SALON uoneoiddy ejdninjy qos 941614 061 A ddng 4008 L WUNnuUIXEN e 08 9141n3e4oduro UMPA SUPE AO 19104 WALSAS lt 43108 30 1NOMJ lt LOSYIGNI Nous NANY 431108 Od 3AlVA 2 034 34155384 JATA 38019 dAL 5 lt lt HIM NALSAS regen MOlVEVd3S OL Alddns 62 Temperature and Flow Requirements existing parallel piping system may be used provided the return water is not below 80 F and the return water temperature is not more than less than the boiler outlet temperature
89. er must only be serviced and repaired by skilled and experienced service technicians If any controls are replaced they must be replaced with identical models Read understand and follow all the instructions and warnings contained in all the sections of this manual If any electrical wires are disconnected during service clearly label the wires and assure that the wires are reconnected properly NEVER operate boiler without all sight glasses and brackets in place and securely fastened and sealed Very HOT combustion gas may cause burn injury Read understand and follow all the instructions and warnings contained in ALL of the component instruction manuals Assure that all safety and operating controls and components are operating properly before placing the boiler back in service 68 IMPORTANT See Section V Item G under Remove all accumulations of soot with wire Operating Instructions if it becomes necessary to add brush and vacuum Remove all obstructions water to the boiler more frequently than once a month Replace all deteriorated parts and support GENERAL Inspection should be conducted annually properly Seal all joints Service as frequently as specified in following 2 CLEAN THE BOILER FLUEWAYS AND paragraphs Refer to Table XII for recommended COMBUSTION CHAMBER periodic testing of safety controls and other equipment a Disconnect the fuel line s and remove the While service or maintenance is being done elec
90. erlap Cut off excess with scissors or utility knife and wooden cutting block d Apply a generous bead of red sealant to both ends of cut rope push ends together and smooth excess sealant over joint with your finger e Locate six 6 3 8 flat washers and six 6 3 8 16 x 1 1 4 12 cap screws from hardware bag Thread one 1 washer and cap screw in each of the bottom tappings approximately four 4 turns Lift flue collector and engage bottom slots over cap screws to position unit on rear section Install remaining hardware in four 4 upper slots and hand tighten hardware Using a wrench tighten hardware evenly use an alternating pattern from top to bottom Do not install Flue Collector Clean out Covers at this time Covers must be installed after Jacket Rear Panels are in place Install 1 4 NPT brass plug into tapping located at 10 o clock position on flue outlet collar Wrench tighten plug but do not over tighten See Figure 9 Apply thread sealant and install 3 pipe plug in lower tapping on front section Wrench tighten until water tight See Figure 9 Install Supply Manifold and 4 NPT nipple See Figure 9 a Locate supply and return manifold carton marked S RM CT and remove contents AXIS OF RELIEF VALVE COUPLINGS b Apply thread sealing compound to both ends of the 4 NPT nipple and install one end of the 4 NPT nipple into the non flow arrowed end of the CI Supply Manifold and hand tig
91. esigned built marked and tested accordance with the ASME Boiler and Pressure Vessel Code Section IV Heating Boilers An ASME Data Label is factory applied to each MPC jacket which indicates the boiler Maximum Allowable Working Pressure MAWP Each cast iron section is permanently marked with the MAWP listed on the boiler s ASME Data Label This value for the MPC is as follows MAWP Water USA and Canada 80 PSI It is common and acceptable practice to install these boilers in lower pressure systems below the boiler Therefore Burnham offers safety relief valves set at or below the MAWP of the boiler See Page 12 for available safety relief valve set pressures TABLE OF CONTENTS SECTION GENERAL INFORMATION Dimensional Information 10 REL 5343 414826 2288 862228 12 Locating the 13 Air Supply Venting 14 SECTION 1 CAST IRON BLOCK ASSEMBLY INSTRUCTIONS Knockdown Boiler Knockdown Boiler w Factory Assembled Section 17 Assembly of Sections Manual Draw Up 18 Assembly of Sections Hydraulic Draw Up 23 Hydrostatic 24 SECTION BOILER ASSEMBLY INSTRUCTI
92. et metal screws as shown in Figure 24c NOTE Torque screws through rear frame rail until tight At this time only snug screws through forward rail s to allow movement in later assembly steps when attaching jacket top corner panels Position channel extension under next horizontal rail secure bracket on extension to previously installed channel with two 2 8 2 lg hex head sheet metal screws Torque these screws until tight Secure front of channel extension to next horizontal rail with two 2 8 x 2 27 lg sheet metal screws Based on block size repeat until chaseway extension has been secured to horizontal rail on front section Install protective edging to raw edges of chaseway channel s Locate JH 1 Hardware Bag packed in JC 1 Jacket Carton From raw stock provided in Hardware Bag cut two 2 pieces of protective On 8 thru 18 sections block assemblies install edging 1 13 16 Ig and two 2 pieces 4 11 16 chaseway channel extension s see Figure 24d long SUPPLY MANIFOLD 4 8 X 2 1 2 HEX HEAD SHEET METAL SCREW HORIZONTAL FRAME RAIL TYPICAL MAIN CHASEWAY CHANNEL PRIMARY JUNCTION BOX VERTICAL FRAME RAIL TYPICAL Figure 24c Internal Wiring Harness Components Install Main Chaseway Channel SUPPLY MANIFOLD 2 8 X 1 2 HEX HEAD SHEET METAL SCREW PRIMARY JUNCTION BOX HORIZONTAL FRAME RAIL TYPICAL CHASEWAY CH
93. ewed From Rear SUPPLY MANIFOLD SLOTTED OPENINGS FOR LOCKING TABS JACKET REAR TOP REAR FRAME Y INTERMEDIATE TOP PANEL 8 X 1 2 LG HEX P d HEAD SMS BURNER SWING DOOR B S D SHOWN OPEN JACKET OUTER TOP CORNER PANEL Step 2 On 8 thru 18 section boilers locate intermediate top panel s and install in order of assembly shown in Table XI Position panel b JACKET FRONT etween outer top corner panes Slide forward m A PANEL to engage locking tabs into slotted openings on previously installed panel see Figure 30b Secure 2 rear flange with two 2 8 x lg SMS Repeat P until intermediate panels reach supply manifold Step 3 Position jacket rear top panel between outer top corner panels behind supply manifold Slide forward until locking tabs are engaged into slotted 83 O al HINGE PIN i LOOP amp openings on previously installed panel Secure EY panel to rear clips on outer corner panels with two 2 8 x V lg SMS Refer to Figure 30c HINGE POCKET L Install Burner Swing Door BSD on Block Assembly hinges see Figure 31 Move BSD to front of boiler Position door on the Floor standing up perpendicular BLOCK ASSEMBLY to front of boiler full open position Figure 31 Install Burner Swing Door 47 48 Important Product Safety Information Refractory Ceramic Fiber Product Warning The Repa
94. f adapter is furnished with burner follow manufacturer s instructions using gasket material and hardware provided with burner 4 SAW OR KNIFE TO CUT BURNER SWING DOOR INSULATION TO MATCH HOLE SIZE ON BURNER ADAPTER PLATE After cutting remove any and all loose pieces of insulation which may become lodged or interfere with the head of the burner air tube after insertion 5 Secure burner to adapter plate with four 4 gt lock washers and four 4 Y2 13 hex nuts provided Beckett CF Series Burner Adapter Plate Boiler Model Part No 1 0 MPC4 thru 602263001 00 6 3 4 8 thru MPC15 602263011 8 1 4 MPC16 thru 18 602263021 10 1 4 Beckett CG Series Burner Adapter Plate Boiler Model Part No 1 0 pcs ana 7 602263041 o4 8 10 2 602268081 08 6 1 _ CAUTION Failure to properly fill all gaps between the insulation and burner blast tube may result in damage to the burner 6 Confirm that hole in insulation fits snugly around burner blast tube If hole is oversized open burner swing door with burner attached to access burner blast tube Use additional fiberglass rope gasket provided with burner to fill in any space between insulation and blast tube If additional rope gasket 18 not provided with the burner use 3 8 fiberglass rope rated for 2300 F provided by others When finished c
95. g hex head Note Right side of boiler uses same panels as left side with a reverse pattern starting at the rear and working forward G Locate Front Panel Shipped in Jacket Carton marked JC 1 Position jacket front panel against front of boiler assembly and feed internal harness wires through holes in side of panel as shown in Figure 25 8 X 1 2 LG HEX HEAD SMS UN SUPPLY MANIFOLD INTERMEDIATE TOP PANEL 5 ies m FRAME RAIL DETAIL A END VIEW PANEL S IN PLACE TOP CORNER PANEL W MOUNTING HOLES LESS BRACKET 8 X 1 2 LG HEX HEAD SMS 8 X 1 2 LG HEX HEAD d SMS FRAME RAILS TYPICAL TOP INTERMEDIATE PANEL W JOINER BRACKET END VIEW SEE DETAILA TOP CORNER PANEL W JOINER BRACKET Figure 26 Install Top Corner Intermediate Panels CORNER PANEL TOPCORNER 7 PANEL gt ES 2 FRONT FRAME RAIL JACKET FRONT __ 4 D PANEL JACKET FRONT PANEL 2 M FRONT FRAME RAIL RECTANGULAR HOLE 11 zx LOCKING HOOK 1 4 LOCKING DETAIL A Figure 27 Install Jacket Front Panel 44 Install front panel by tilting on a slight angle to engage H Locate Jacket Split Rear Panel shipped in JC 1 Jacket top flange behind bottom flange on jacket top corner Carton panels installed previously see Fig
96. g keyway slot in loop over pocket key to lock position see Figure 11 Attach each hinge loop with one 1 7 16 split lock washer and one 1 7 16 14 x 1 1 2 lg cap screw secure hardware wrench tight 26 POCKET KEY 7 16 14 X 1 1 2 LG CAP SCREW 7 16 SPLIT LOCK WASHER HINGE POCKET ON B S D REAR VIEW MACHINED HINGE LOOP W KEYWAY SLOT Figure 11 Hinge Loop 5 For BSD right hand swing right side hinge a Repeat 4a thru 4d but install hinge set and hardware in reverse locations for right hand swing 6 Complete Burner Swing Assembly BSD see Figure 9 a Install BSD rope gasket to rear of door b If necessary clean the rope groove around perimeter of the BSD with a wire brush c Using the multi purpose spray adhesive provided apply the adhesive to the perimeter rope groove Follow the directions on the can for application and tack time d Locate a 158 length of silicone coated fiberglass rope from common parts carton Starting at 3 o clock position push rope into groove and continue around perimeter until rope overlaps the starting point Rope should be approximately 4 longer than required Use a permanent black marker to mark the rope approximately 1 8 beyond point of overlap Cut off excess with scissors or utility knife and wooden cutting block e Apply a generous bead of red sealant to both ends of cut rope push ends together and
97. g port in Figure 1b To obtain the above a factory supplied MPC Flue Outlet Damper Assembly see Page 56 for details must be attached directly to the Rear Flue Collector Outlet If the venting system is designed for positive or forced draft venting the boiler vent connector and stack will operate under positive pressure Gas tight vent systems designed for pressure systems must be used to prevent flue by product leakage The vent height is usually limited to prevent negative draft typically three 3 feet above the roof line see Figure 3a The damper shall be adjusted to maintain a positive pressure of 0 1 W C at the flue outlet during burner high fire operation If the venting system is designed for negative pressure natural draft the boiler still operates with positive pressure in the chamber and up to the fixed damper on the flue collar However if the venting system 15 larger than what is required the stack will provide a surplus draft or negative pressure that may require the use of a barometric damper to maintain the positive 0 1 W C pressure at the flue outlet Multiple forced draft boiler stacks should always be designed as negative to ensure the products of combustion do not exit a boiler that is not firing When gas fired boiler is connected to a venting system that is designed so that it will operate under a negative pressure the use of Type B or other manufactured vent systems de
98. harge piping If discharge is weeping do not plug relief valve or cap discharge piping replace valve immediately INSTALL ELECTRIC WIRING in accordance with National Electric Code and local regulations A separate ELECTRICAL CIRCUIT should be run from meter with a Fused Disconnect Switch in this Circuit VALVE OUTLET PIPED TO DRAIN RETURN MANIFOLD Ox DISCHARGE TO FLOOR OR DRAIN C PS REAR OF BOILER 1 FLOOR 28 CI FLOOR LINE LINE REAR VIEW PARTIAL SIDE VIEW Figure 54 Discharge Piping for Pressure Relief Valve 64 SECTION V OPERATING INSTRUCTIONS WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage or personal injury If any unusual or improper operation or site condi tions are observed turn the boiler off and contact an experienced and skilled service agency Follow component manufacturer s instructions Component manufacturer s instructions were provided with the boiler Contact component manufacturer for replacement if instructions are missing Do not install start up operate maintain or service this boiler without reading and understanding all of the component instructions Do not allow the boiler to operate with altered disconnected or jumpered components Only use replacement components identical to those origin
99. hout the assembly procedure until depleted KNOCKDOWN BOILER EQUIPMENT CHECK LIST Carton Qty Req d Per Boiler Size Designation Part oT _ 1 4141 41 41 Component Description ea Code Number Label 2 21 11 Castings Shipped Loose Field Assembly B Figure 1a Carton Identification MPC Common Castings amp Parts Skid Includes Front Section Rear Section Burner Swing Door Assembly Rear Flue Collector and Miscellaneous Common Parts Carton Center Section Machined Quantity shown shipped on separate MPC C 100657 01 2 31 4 5 7 10 11 12 13 14 15 16 skid s Maximum 6 per skid Parts Cartons saca 08561 11111 1 sacs forsara 3 Boiler Assembly Cartons 2 101831 04 101831 05 5 101831 06 S RM CI RWMT 4 RC RWMT5RC 102804 05 RWMT6RC 102804 06 RWMT7RC 102804 07 8 102804 08 RWMT9RC 102804 09 RWMT 10 102804 10 Return Water Mixing Tube Cartons Restricted Clearance RWMT 11 RC 10280411 RWMT 12 RC RWMT 13 RC RWMT 14 RC RWMT 15 RC RWMT 16 RC RWMT 17 RC RWMT 18 RC Jacket Jacket Frame Frame Front Center Rear Rails 101934 02 Cartons Jacket Frame Center Rails JF 3 101834 03 18 Continued KNOCKDOWN BOILER EQUIPMENT CHECK Contin
100. hten the assembly c Then Install the threaded end of the 4 nipple into 4 NPT tapping located on top of rear section d Wrench CI Supply Manifold Assembly until water tight and 1 2 tappings relief valve are aligned with front and rear axis as shown in Figure 12 SUPPLY MANIFOLD FRONT amp REAR AXIS OF CASTINGS ut REAR SECTION W 4 TOP SUPPLY TAPPING Figure 12 Orientation of Supply Manifold NOTICE Orientation of supply manifold is critical for proper alignment of controls and relief valve pipi ng B Assemble and Install Return Water Mixing Tube RWMT RC and Return Manifold into Block Assembly 1 Locate return water mixing tube carton marked RC and remove contents Modular return water mixing tubes start as a two 2 tube assembly with end cap and increase with block size to become a seven 7 tube assembly with end cap Assemble each RWMT RC in exact order shown in Table VII based on boiler size Also refer to Figure 13 Per Table VII starting at the front install RWMT End Cap on tube shown in next column to the right Open RH hardware bag and locate 3 oz tube of sealant Apply a continuous bead of silver silicone sealant to end of tube opposite the flared collar or ring The end cap and each tube has a series of holes for alignment when secured together Align the holes push end cap over tube end with sealant and secure with four 4 48
101. ia pressure plate 34 flat washer and hex nut as shown in Figure 5 Insert one assembly through each of the 3 and 4 NPT bosses on rear section until pressure plate is tight against the boss Locate and place the 834 dia pressure plate on the opposite end of threaded rod in upper nipple port Place remaining 6 2 dia pressure plate on rod protruding through lower nipple port Install a 34 washer 34 coupling spacer 34 washer and 34 hex nut on each rod Center upper pressure plates on nipple port and boss while tightening nut until tension holds assembly in place Repeat for lower assembly Refer to Figure 5 to verify proper arrangement Step n DRAW UP SECTION SLOWLY AND EVENLY When you start machined surfaces between adjoining sections should be approximately 3 8 to 1 2 apart The 7 nipple will pull harder than the 3 nipple If two 2 people are pulling simultaneously stop periodically to verify that gaps between adjoining sections are equal at both nipple ports If not pull the nipple with the larger gap until equal before proceeding Continue draw up paying close attention to the nipple lubricant as it squeezes when the sections come in close contact The lubricant should continue to squeeze out until the sections are connected metal to metal at the designated inspection pads shown in Figure 8 If the sections still do not appear to be drawn metal to metal use the feeler gauge provided to measure any
102. ications Table XIVc 75 Power Flame Combination Gas 2 Oil Burner Specifications 107 Limited Warranty For Commercial Grade Boilers Using Cast Iron Carbon Steel or Stainless Steel Heat Exchangers and Parts Accessories Subject to the terms and conditions set forth below Burnham Commercial Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water or steam boiler or Burnham Commercial supplied parts and or accessories manufactured and shipped on or after October 1 2009 ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS AND PARTS ACCESSORIES SUPPLIED BY BURNHAM COMMERCIAL Burnham Commercial warrants to the original owner that its commercial grade water and steam boilers and parts accessories comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation If any part of a commercial grade boiler or any part or accessory provided by Burnham Commercial is found to be defective in material or workmanship during this one year period Burnham Commercial will at its option repair or replace the defective part not including labor HEAT EXCHANGER WARRANTIES Burnham Commercial warrants to the original owner that the heat exchanger of its commercial grade boilers will remain free from
103. ill the boiler Add boiler water treatment compound as needed Restore electric service to the boiler Doom Fire burner to bring the water in the boiler to a boil to drive off free oxygen s BEFORE RETURNING BOILER TO SERVICE Follow the low water cutoff check out procedure see Section V Paragraph E Item 3 FLOAT TYPE LOW WATER CUTOFF During the heating season if an external low water cutoff is on the boiler the blow off valve should be opened once a month use greater frequency where conditions warrant to flush out the sediment chamber so the device will be free to function properly Low water cutoffs should be dismantled annually by qualified personnel to the extent necessary to insure freedom from obstructions and proper functioning of the working parts Inspect connecting lines to boiler for accumulation of mud scale etc and clean as required Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and that they function properly Give special attention to solder joints on bellows and float when this type of control is used Check float for evidence of collapse and check mercury bulb where applicable for mercury separation or discoloration DO NOT ATTEMPT TO REPAIR MECHANISMS IN THE FIELD Complete replacement mechanisms including necessary gaskets and installation instructions are available from the manufacturer CHECK BURNER AND CONTROLS at lea
104. in place to the boiler water for a scale or sediment buildup h Light deposits may be removed by wiping the probe with a damp cloth Wiping the probe with a cloth soaked in vinegar will remove more tenacious lime deposits The most stubborn deposits may be removed from the probe by using a diluted amount 3 part of water to 1 part f Connect the fuel lines of phosphoric acid H PO g Reattach the BSD cover panels if provided e Reinstall the burner to the BSD if removed and secure it in place on its support pedestal Inspect the burner gasket to assure an adequate seal Replace it if damaged 69 WARNING Exercise caution when handling phosphoric acid and follow the instructions on container label Always use protective clothing and equipment when working with near chemicals 70 i Wire brushing of the probe is not recommended as the soft platinum guard ring sandwiched between the ceramic insulators may be damaged Care must be taken not to damage this ring in any way or the useful life of the probe may be shortened j Clean the pipe threads of the probe to remove old hardened pipe dope and other foreign matter k Apply a moderate amount of good quality pipe dope to the pipe threads on the probe leaving the two end threads bare Do not use PTFE Teflon tape Screw the probe into the boiler tapping Mount the low water cutoff control on the probe Reconnect the control to probe wiring H
105. in premature boiler failure through thermal shock WARNING Appliance materials of construction products of combustion and the fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides aldehydes and or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer birth defects and other reproductive harm Always use proper safety clothing respirators and equipment when servicing or working nearby the appliance This boiler contains very hot water under high pressure Do not unscrew any pipe fittings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure Always wear protective clothing and equipment when installing starting up or servicing this boiler to prevent scald injuries Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler This boiler contains components which become very hot when the boiler is operating Do not touch any components unless they are cool This appliance must be properly vented and connected to an approved vent system in good condition Do not operate boiler with the absence of an approved vent system This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air The interior of the venting and air intake systems must be inspected
106. in the center of the tapped hole both vertically and horizontally b If necessary adjust support collar position before installing front support plug For horizontal adjustment bend support clip up or down per the amount of visual mis alignment c Thread front support plug into 3 NPT upper front section boss wrench plug water tight C Install Jacket Support Frame to Block Assembly 1 Locate Jacket Frame Carton s marked JF and remove contents see equipment list on Page 3 for quantity required the tube into position 2 Open Jacket Frame Parts Carton s packed Install CI Return Manifold and 4 NPT Nipple See inside Jacket Frame Carton s and remove contents Figure 9 3 Locate support channel brackets which are shipped a Apply thread sealing compound to both ends of 21 by both 4 nipple and hand tighten nipple into one end of the CI Return Manifold return manifold JACKET SUPPORT casting is symmetrical about the ends lt SHIPPED FLAT b Slide the CI Return Manifold Assembly over RWMT and install the threaded end of the 4 NPT nipple into 4 NPT tapping in rear section gt Et c Wrench CI Return Manifold Assembly until AC gt watertight and 2 NPT tappings positioning 1 lt a T plugs are aligned with vertical axis of rear x section as shown in Figure 14 1 REAR SECTION RETURN COMES DOWN 90 TYP BOTH SID
107. installed maintained and operated in accordance with these instructions DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Failure to follow all instructions in the proper order can cause personal injury or death Read and understand all instructions including all those contained in component manufacturers manuals which are provided with the appliance before installing starting up operating maintaining or servicing this appliance Keep this manual and literature in legible condition and posted near appliance for reference by owner and service technician This boiler requires regular maintenance and service to operate safely Follow the instructions contained in this manual Installation maintenance and service must be performed only by an experienced skilled and knowledgeable installer or service agency All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed Installation is not complete unless a pressure relief valve is i
108. ir Parts list designates parts that contain refractory ceramic fibers RCF RCF has been classified as a possible human carcinogen When exposed to temperatures about 1805 such as during direct flame contact RCF changes into crystalline silica a known carcinogen When disturbed as a result of servicing or repair these substances become airborne and if inhaled may be hazardous to your health AVOID Breathing Fiber Particulates and Dust Precautionary Measures Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear A National Institute for Occupational Safety and Health NIOSH approved respirator Long sleeved loose fitting clothing Gloves Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an airtight plastic bag RCF and crystalline silica are not classified as hazardous wastes in the United States and Canada First Aid Procedures If contact with eyes Flush with water for at least 15 minutes Seek immediate medical attention if irritation persists If contact with skin Wash affected area gently with soap and water Seek immediate medical attention if irritation persists If breathing difficult
109. is b happens the cast iron in that area gets extremely hot and eventually cracks The presence of free oxygen in the boiler creates a corrosive atmosphere which if the concentration becomes high enough can corrode the Eliminating open tanks from the system c Eliminating and or repairing fittings which allow oxygen absorption d Use of non permeable materials in the distribution cast iron through from the waterside Since neither of system these failure types the result of a casting defect the e Isolating the boiler from the system water by warranty does not apply Clearly it is in everyone s best installing a heat exchanger interest to prevent this type of failure The maintenance of system integrity is the best method to achieve less makeup water 67 SECTION VI SERVICE INSTRUCTIONS DANGER This boiler used flammable gas high voltage electricity moving parts and very hot water under high pressure Assure that all fuel and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service More than one gas shut off valve and electrical disconnect switch are used on the boiler Assure that all gas valves and electrical disconnect switches are off before attempting any disassembly or service Do not attempt any service work if gas is present in the air in the vicinity of the boiler Never modify remove or tamper with any control device WARNING This boil
110. l Information Figure 1b 10 Figure 2 14 Figure 3a 15 Figure 3b 16 Appendix A Figures Page Number Description Carton Identification Dimensional Information Boiler Foundation MPC With Rear Outlet Vent Vents Faults and Suggestions Section Cast Iron Block Assembly Instructions Knockdown Boilers Lifting Instructions Limited to 4 thru 12 Section Block Assembly No Steel Base Lifting Instructions 4 thru 18 Section Block Assembly w Steel Base Manual or Hydraulic Draw up Section Assembly Vertical Bracing of Rear Section Setting of Nipples Inspection Pad Locations for Section Draw up Section III Boiler Assembly Instructions Knockdown Boiler 104 Figure 4a 17 Figure 4b 17 Figure 5 19 Figure 6 20 Figure 7 20 Figure 8 20 Figure 9 25 Figure 10 26 Figure 11 26 Figure 12 27 Figure 13 29 Figure 14 30 Figure 15 30 Figure 16 31 Figure 17a 32 Figure 17b 32 Figure 18a 33 Figure 18b 33 Figure 19 34 Figure 20 34 Figure 21 35 Figure 22 36 Figure 23 37 Figure 24a 38 Figure 24b 38 Figure 24c 39 Figure 24d 39 Figure 24e 40 Figure 24f 40 Figure 24g 41 Installation of Common Parts to Block Assembly Universal Hinge Latch Casting Hinge Loop Orientation of Supply Manifold Return Water Mixing Tube Reduced Clearance Assembly and Installation Orientation of Return Manifold Hand Form Support Channel Bracket Secure Bracket to Horizontal Channel Front Center Section Horizontal Channel Assembly w
111. lants silastics manufactured by Dow Corning under the product number RTV 736 and Sil Bond under the product number RTV 6500 WARNING Sections must be drawn up tight immediately after properly applying sealant for best results Although sections may be joined within two 2 hours of applying sealant humidity and temperature affect cure time If a thick skin has been formed on the sealant bead remove and re apply sealant Step k Position the next adjoining section to be assembled so that the side with the sealing tongue around the combustion chamber and perimeter is facing the mating side of the rear section Sections must always be assembled so that the rope groove on one section mates to the sealing tongue on the next section in the assembly Step Clean and lubricate the nipple ports on the mating tongue side of the adjoining section Place the nipple ports of the adjoining section onto the nipples previously installed in the rear section To facilitate assembly it is advisable to enter the upper nipple first in its port Then enter the lower nipple in it s respective port If necessary place a lifting bar crowbar under the center of the section and lift the nipple port onto the upper nipple Drive section in place with a heavy block of wood striking blows as squarely as possible over nipple ports Step m From Manual Draw up Kit locate and assemble two 2 sets that include a 34 x 23 lg threaded rod 6 2 d
112. ld be applied before each section is placed on the assembly Step g Use the Loctite 592 lubricant supplied to lubricate the nipples and nipple ports Apply the lubricant to the nipples and nipple ports then use a brush to disperse it evenly around the nipples and nipple ports Use approximately 20 ml of lubricant per flueway 1 7 and 1 3 nipple and their corresponding nipple ports 2 in the rear section and 2 in the next adjoining section Step h Drive nipples squarely into section using block of wood and hammer or preferably an aluminum head hammer Burnham offers a polyethylene block for setting the nipples part no 8052601 Place block over entire nipple edge and hit the wood or polyethylene block with the hammer NOTICE Nipples must be driven in evenly and to the proper depth to assure tight joints Most nipple leaks are caused by tilted or cocked nipples DO NOT use sieel iron head hammer to drive nipples without using a wood or polyethylene block Nipple damage may result Step i A special nipple setting gauge is provided for the nipples Gauge nipple at 90 angles to insure that it is driven to the proper depth into the nipple opening nipple port Cut out in gauge must rest on nipple with the legs of the gauge touching finished face of section when nipple is properly driven See Figure 7 Step Apply a generous bead of RTV 6500 or RTV 736 sealant to the 4 flueway sealing grooves on
113. lose burner swing door and secure hardware P Connect Internal Control Safety Circuit Wiring Harness to Burner Controls see Figures 25 and 37 Also refer to Burner Installation Manual and wiring diagrams provided with burner 51 JACKET FRONT PANEL WIRING HARNESS COVER PLATES 8 X 12 HEX HEAD SMS SNAP IN le HOLE PLUG 2 2 LEADS 7 WIRES PER BUNDLE m e INSTALLATION OF WIRING HARNESS COVER PLATES 8 HEX HEAD SMS POSITIONING SNAP IN HOLE PLUG BOILER LOGO PLATE INSTALLATION OF BOILER LOGO PLATE Figure 37 Install Jacket Front Panel Harness Cover Plates and Logo Plate 1 Harness is split into two 2 7 wire bundles that exit side of front panel as shown in Figure 25 2 Each seven 7 wire harness bundle must be encased in flexible conduit from cover plate to burner control 9 Connect other end of flexible conduit to burner control panel or junction box Connect control safety circuit wires to appropriate terminals per wiring diagram provided with burner panel or junction box Q Install Logo Plate on Jacket Front Panel if Optional 3 Locate front panel cover plates in JC 1 carton 4 Determine routing length and type of BX connectors to be used on flexible conduit 5 Mount BX connector and flexible conduit to one 1 front panel cover plate Pull wire bundles through conduit 6 Secure cover plate t
114. ly Lay channel assembly on floor with brackets facing up see Figure 17b Install hardware as shown with one 1 1 3 4 Ig spacer between bracket legs one 1 engaging upper slot over threaded tie rod rotate washer and one 1 hex nut on one end of 3 8 16 bracket around rod until lower slot is aligned with x 13 3 8 Ig threaded rod with one 1 washer lower hole in casting leg Insert 5 8 11 x 2 lg bolt with washer through cast hole in leg and slot in bracket Table VIII Frame Bracket Mounting Locations Front Block Assembly 2 Rear Boiler Size asenon Reasedo o Front Section Reasedon eseon Front Seaton Rearsedon _ 7secion Front Seaton Seaton ___ Seaton RewSedo ___ Seaton RearSeoton section Front Section Section Front Seaton Seaton _ ___ Seaton ___ Sections Section __ Sections Sesion 10 Rearseton Section 1 __ section Seron __ 31 4 3 8 FLAT WASHER 2 7 16 X 1 2 LG SPACER 2 3 8 HEX NUT
115. n Bracket to Casting Leg 5 8 FLAT WASHER 5 8 11 X 1 1 2 LG HEX HEAD BOLT LOWER REAR SECTION BRACKET REAR SECTION 5 8 5 8 FLAT WASHER 247 Figure 20 Attachment of Lower Rear Section Bracket to Casting Leg 34 Hand tighten 1 5 8 washer and hex nut on Hand tighten one 1 5 8 washer and hex nut on bolt Do not wrench tighten at this time Repeat for bolt Do not wrench tighten at this time Repeat for all front center brackets both sides bracket on opposite side 11 Locate and install rear section brackets to casting 12 Locate and secure vertical side channels painted legs Brackets are universal and can be used on black to horizontal top channels and lower brackets either side of block assembly Brackets mount to Position side channel so pilot hole on channel face front surface of leg with offset toward the rear as is located at the top see Figure 21 Engage flanges shown in Figure 20 Hold bracket at a 45 angle on vertical side channel over flanges on horizontal while engaging upper slot over threaded tie rod channel and secure with two 2 8 x 1 2 sheet metal rotate bracket around rod until lower slot is aligned screws Engage vertical side channel flanges over with lower hole in casting leg Insert 5 8 11 x 2 lower bracket move bracket as necessary to align lg bolt with washer through cast hole in leg and slot holes secure channel with two 2 8
116. n in next column NPT tappings If necessary push forward or pull to the right in Table VII also refer to Figure 13 back on RWMT assembly and or rotate until pins on for details If space behind the boiler is limited positioning plugs engage alignment holes in tube on RWMT s having two or more tubes it may be see Figure 13 Wrench both plugs until water tight necessary to assemble the end cap to the adjoining 7 Install RWMT front support plug into 3 NPT tube and then insert the assembly capped end first into the 4 NPT tapping on the back of the rear section before joining the remaining tube s Allow approximately 192 of the tube to protrude from the tapping so that the next tube can be secured to the assembly Once the next tube is secured insert the assembly further into the tapping Repeat this procedure as necessary for up to seven 7 tube RWMT assemblies Insert the completed RWMT assembly into the 4 NPT tapping until the end cap reaches the front of the boiler The front support clip on the end cap must rest on the internal shelf inside of the upper 3 NPT boss on the front section If necessary insert a long screw driver wooden dowel or a short length of 1 2 pipe through the 3 NPT tapping and into the support collar on the end cap to lift and maneuver tapping on upper front section boss a Looking through 3 tapped hole check position of support collar on RWMT end cap Collar should be located approximately
117. nd 3rd Pass Flueway Baffles Figure 64 98 100 MPC Standard 50 PSI Trim amp Control with 30 PSI and 80 PSI Working Pressure Trim Options Description 99 101 Standard Water Trim amp Control and Optional Working Pressure Trim Figure 65 102 MPC Optional Controls Description 103 Common Optional Controls Appendix Tables Table Number Page Number Description Section General Information Table 11 Dimensional Information Table 12 Ratings Data Table 13 Recommended Rear Service Clearance Table IV 13 Minimum Installation Clearances to Combustible Materials Table V 14 Boiler Foundation Section Cast Iron Block Assembly Instructions Knockdown Boiler Table VI 22 Proper Arrangement of Threaded Rods and Coupling Nuts Section Boiler Assembly Instructions Knockdown Boiler Table VII 28 Modular Return Water Mixing Tube RWMT RC Table VIII 31 Frame Bracket Mounting Locations Table IX 41 Internal Wiring Harness Adjustment Table X 43 Jacket Top Corner Intermediate Panel Arrangement Table XI 46 Jacket Top Panel Arrangement Section IV Installation Instructions Section V Operating Instructions Section VI Service Instructions Table XII 71 72 Recommended Periodic Testing Check List Section VII Burner Specifications Table 73 Beckett 2 Burner Specifications Table XIIIb 73 Beckett Gas Burner Specification Table 74 Power Flame 2 Oil Burner Specifications Table XIVb 74 Power Flame Gas Burner Specif
118. ng positioning tabs on rear of Logo Plate into slotted openings in upper left corner of left cover panel as shown in Figure 47 amp S D Figure 47 Install Jacket Panels for Optional Burner Swing Door Cover 57 SECTION IV INSTALLATION INSTRUCTIONS A PACKAGED BOILER The packaged boiler comes on its own shipping WARNING skid see Figure 48 and the assembled block is Failure to properly pipe boiler may result in hydrostatically tested at the factory Once the boiler improper unsafe system operation and void is in its final position PERFORM ANOTHER manufacturer s warranty HYDROSTATIC TEST AT 1 TIMES THE WORKING PRESSURE OF THE BOILER see Section II Paragraph C The shipping skid can be used as a housekeeping pad unless local codes say otherwise Most controls are pre wired down to the burner If burner is equipped with a lead lag panel All hot water pipes must have clearances of at lead lag controls will be shipped loose for header least 1 2 from all combustible construction mounting The power can be supplied to the burner if equipped with a control panel If burner has no DO NOT improperly pipe boiler panel the power must be supplied to a junction box WARNING hot water boiler installed above radiation level 2 If the boiler burner unit was factory fire tested must be provided with a low water cutoff device the burner was adjusted to approxim
119. ng harness components 2 Locate junction boxes shipped in Jacket Frame Carton marked As viewed from the rear INTERNAL CONTROL SAFETY CIRCUIT HARNESS NYLON WIRE TIES 2 SECONDARY J BOX Y CONNECTORS PRIMARY J BOX 5 74 sveeve 7 PROTECTIVE amp BOGE TRIM 7 22 ENDS PROTECTIVE EDGE TRIM HORIZONTAL FRAME RAIL TYPICAL SECONDARY JUNCTION BOX W SECURING CHANNEL CHASEWAY CHANNEL EXTENSION SUPPLY MANIFOLD CHASEWAY CHANNEL PRIMARY JUNCTION BOX FRAME RAIL TYPICAL Figure 24a Internal Wiring Harness Components SECONDARY JUNCTION BOX SECURING CHANNEL 7C 4 8 X 1 2 HEAD SHEET METAL SCREW PRIMARY JUNCTION BOX E SUPPLY in EE MANIFOLD HORIZONTAL RAIL Figure 24b Internal Wiring Harness Components Mounting Junction Boxes 38 Locate chaseway channel s shipped in Jacket Carton marked JC 2 see Figures 24c and 24d Identify main chaseway channel by it s unequal ends Install the end with 8 47 lg side flange under horizontal rail and through openings in junction box until end protrudes past rear horizontal channel Secure main chaseway channel to both horizontal frame rails using 8 x 2 2 lg hex head she
120. nimum Supply Water Temperature 130 F COLD WATER SYSTEM PUMP SUPPLY ils 2 AIR SEPARATOR WITH AIR VENT GLOBE VALVE 2 2 y 3 RETURN PRESSURE H REDUCING I _ VALVE v ISOLATION 75 VALVES lt Y ds 1 SUPPLY TO INDIRECT WATER 5 DIAPHRAGM _ gt lt N TANK 4 SUPPLY _ MANIFOLD Y ISOLATION VALVE RETURN FROM INDIRECT WATER Le wu T HEATER S IWH 4 RETURN MANIFOLD X E N ISOLATION VALVE 55 2 lt 7 p d nr 7 DRAIN VALVE 2 SEE NOTE 4 ert REAR OF BOILER 1 Supply 2 Return 20 F Rise 40 F Rise NOTES Boiler 2504 Model e Water Side Water Side 1 All piping is schedule 40 pu Press Drop pH h Press Drop 2 Pipe sizes listed are based on a 20 Inc Ft Wir Inc FUWtr or 40 F Delta T temperature rise 2 across the boiler Bue Rr Select one to match application BW When specified piping size is less than 4 install appropriate size reducer EET 2 102 3 directly onto boiler supply and return 1884 020 Pct 68 167 size ASME code is 3 4 NPT 195 2 5 Swing joints be piped over the top of the boiler if space is limited EE 9s 10s 99 116 1 6 System design must accommodate the 125 5 above Boil
121. nstalled into the specified tapping on the supply manifold located on top and at rear of appliance See Section Paragraph R 3 of this manual for details All boiler builds except boilers bearing the UL Label are suitable for installation on combustible flooring Do not install boiler on carpeting Do not operate on floors where heat affected material is below Do not tamper with or alter the boiler or controls Retain your contractor or a competent serviceman to assure that the unit is properly adjusted and maintained Clean boiler at least once a year preferably at the start of the heating season to remove soot and scale The inside of the combustion chamber should also be cleaned and inspected at the same time Have Burner and Controls checked at least once a year or as may be necessitated Do not operate unit with jumpered or absent controls or safety devices Do not operate unit if any control switch component or device has been subject to water This boiler is designed to operate with lower return water temperatures and avoid thermal shock and accumulation of condensate if operated per the following criteria o Minimum Return Water Temperature 80 F Maximum Delta T Between Boiler Supply and Return 80 F Minimum Supply Water Temperature 130 F Continued operation beyond these limitations will result in sustained condensing within the combus tion chamber and potentially reduce boiler longevity and may result
122. o side of jacket front panel using 2 8 x 1 2 lg hex head SMS 7 Locate and install one 1 plastic hole plug provided into unused 7 8 dia hole in cover plate 8 Install remaining cover on opposite side of front panel Secure with 8 x 1 2 lg hex head SMS push 3 plastic hole plugs into 7 8 dia holes REAR OF BOILER FRONT OF BOILER Jacket Split Burner Swing Door Cover Panels are not to be used Locate Logo Plate shipped in Instruction Envelope Peel paper off adhesive strips and install by inserting positioning tabs on rear of Logo Plate into slotted openings located at top of front panel shown in Figure 37 If optional BSD cover panels are used Logo Plate will be installed on the cover as instructed in later steps Locate Water Trim and Control Carton marked WT and remove contents Check Equipment Check List for proper working pressure relief valve Install standard trim and controls as follows 1 See Figure 38 for purpose of tappings on supply manifold Size of Tapping Purpose of Tapping A 4 Flange Supply Relief Valve C Auxiliary Tapping Plug 3 3 y Operating Temperature Limit Control Probe LW C O High Temperature Limit Control Manual Reset Temperature Pressure Gauge Low High Low or Modulating Control Low Fire Hold Control 3 Supply Manifold must be installed with 19 coupling B Figure 38 Purpose of Tappings in Supply
123. of time Burnham Commercial liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the commercial grade boiler involved 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 8 Limitation of Warranties These warranties set forth the entire obligation of Burnham Commercial with respect to any defect in a commercial grade boiler parts or accessories and Burnham Commercial shall have no express obligations responsibilities or liabilities of any kind whatsoever other than those set forth herein These warranties are given in lieu of all other express warranties ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE HEAT EXCHANGER IN A COMMERCIAL GRADE BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE OF INSTALLATION SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty service the owner is requested to complete and mail the Warranty Card provided with the product or register product online at www
124. on each side Pull both sides of insulation back between vertical channel and rear casting Open slit at bottom and position over lower rear bracket Tuck bottom edges behind lower tie bar Center Insulation Wrapper s 12 thru 18 Section Block Assembly Drape center wrapper over block assembly align top notches with top frame rail brackets Push insulation behind top and side frame rails along both edges front and rear Tuck bottom edges behind lower tie bars Front Insulation Wrapper Drape Wrapper over Block Assembly Starting in the front at the top pull insulation under horizontal channel Open slits and pull insulation around top brackets On each side pull insulation between vertical channel and front section position around door hinge pockets Open slit at bottom and position insulation around lower front bracket Push rear edges of insulation behind center section frame rails Tuck bottom edges behind lower tie bars 37 E Installing Internal Wiring Harness for Control Safety install primary junction box without extension Circuits refer to Figures 24a through 24g piece to horizontal channel on the left side of supply manifold using two 2 8 x Ig hex head sheet metal screws see Figure 24b Install secondary junction box with extension piece to horizontal channel on right side of supply manifold using two 2 8 lg sheet metal screws 1 See Figure 24a for layout of Internal wiri
125. ont amp Center Section Frame Rail Assembly 82 Rear Section Frame Rail Assembly 84 Return Water Mixing Tube eene enne nnn nnne nnn nnne nnn nnn 86 Heat Exchanger Insulation 88 Internal Wiring Harness Components 90 Jacket Panel cene eec Leere te ccce nene rra annone dna nana mE Dra nime dra 92 274 and 34 Pass Flueway Baffles iia 96 Standard Water Trim and 15 98 Optional Working Pressure Trim eeeeeeeeeeeeees nnn nnn nn nina ens 100 Optional 5 22 ait 102 APPENDIX A LIST OF FIGURES 2 104 APPENDIX B LIST ee 107 WARRANTY REAR COVER uoneunoju 5
126. ould automatically restart during fill unless low water cutoff control requires manual reset Close relief valve when water flows out discharge piping OPEN SUPPLY AND RETURN ISOLATION VALVES RESET OPERATING CONTROL CAUTION Probe and float type low water cutoff devices require annual inspection and maintenance Refer to Section VI step C for proper cleaning instructions BOILER AND SYSTEM CLEANING water side A qualified water treatment chemical specialist should be consulted for recommendations regarding appropriate chemical compounds and concentrations which are compatible with local environmental regulations 66 water heating system the boiler and entire system other than the expansion tank must be full of water for satisfactory operation Water should be added to the system until the boiler pressure gauge registers normal system design operating pressure To insure that the system is full water should come out of all air vents when opened Boiling Out of Boiler and System The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner a Remove safety relief valve using extreme care to avoid damaging it b Add an appropriate amount of recommended boilout compound Reinstall safety relief valve Hill the entire system with water Start firing the boiler Circulate the water through the entire system Vent the system inclu
127. r Wrappers D Locate and Install Heat Exchanger Block Assembly Insulation Wrapper s see Figure 23 1 4thru 6 Section Block Assembly Insulation wrapper is provided as one piece that covers block from front to rear Drape insulation wrapper over block assembly with supply manifold hole to the rear Starting at top rear pull insulation under horizontal channel open slits and pull insulation around supply manifold and top brackets on each side Pull both sides of insulation back between vertical channel and rear casting Open slit at bottom and position over lower rear bracket In the front starting at the top pull insulation under horizontal channel Open slits and pull insulation around top brackets On each side pull insulation between vertical channel and front section position around door hinge pockets Open slit at bottom and position insulation around lower front bracket Tuck bottom edges behind lower tie bars 2 7 thru 18 Section Block Assembly Insulation wrapper is provided in modular pieces that fit between and join behind each frame rail If the insulation width matches the distance between frame rail brackets it s the proper size for that location Rear Insulation Wrapper Starting at the rear drape rear wrapper over block assembly with supply manifold hole facing the rear as shown in Figure 23 Pull insulation under horizontal channel open slits and pull insulation around supply manifold and top brackets
128. rankcase oil using a gun with an extended stem so as to reach all corners 2 Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time 3 To recondition the heating system in the fall season after a prolonged shut down follow the instructions outlined in Section V Operating Instructions Table Recommended Periodic Testing Check List Gauges and Indicators Instrument and Equipment Settings Firing Rate Control Weekly Semiannually Annually Make visual inspection and record readings in log Make visual check against recommended specifications Operator Service Technician Service Technician Verify factory settings Verify factory settings Check with combustion test Flue Vent Stack or Monthly Operator Make visual inspection of linkage Outlet Dampers Check for proper operation Igniter Fuel Valves Pilot and Main Pilot and Main Gas or Main Oil Annually Combustion Safety Controls Flame Failure Flame Signal Strength Pilot Turndown Tests As required annually Make visual inspection Check flame signal strength if meter fitted See Combustion Safety Controls Operator Open limit switch Make aural and visual check Check valve position indicators and fuel meters if so fitted Service Technician Perform leakage tests Refer to burner instructions Operator Close manual fuel supply for 1 pilot 2 main fuel cock and or val
129. s NOTE 3 For reduced clearances to combustible material protection must be provided as described in the above ANSI NFPA 31 Standard 13 Table V Minimum Installation Clearances To Combustible Materials Inches per UL726 Packaged Firetested Boiler C a i SIDE OF i BOILER BOILER zJ 2 ipia C A B Chimney D E F Boiler Above Front Connector Rear Sides Below MPC 18 48 18 18 18 NC Noncombustible Flooring Note See Table for recommended service clearance to access rear of boiler NOTE 1 Listed clearances comply with UL 726 Standard for Oil Fired Boiler Assemblies NOTE 2 MPC Series boilers can be installed in rooms with clearances from combustible material as listed above Listed clearances cannot be reduced for alcove or closet installations 3 PROVIDE ADEQUATE FOUNDATION for the unit Refer to Figure 2 WARNING boiler builds except boilers bearing the UL Label are suitable for installation on combustible floor Do not install boiler on carpeting Floor construction should have adequate load bearing characteristics to bear the weight of the boiler filled with water see Table 1 A boiler foundation similar to the one shown in Figure 2 is recommended if the boiler room floor is weak or uneven or if a water condition exists 4 PROVIDE AIR SUPPLY AND VENTILATION to accommodate proper combustion
130. s or greater than the boiler breeching Smoke Outlet A barometric damper may be required on installations with a high draft condition FAULTY BOILER BURNER OPERATION 1 If improper vent is suspected remove pipe at breeching and operate boiler This will determine if excessive down draft blocked or restricted flue etc is causing the problem 2 If using type shown in A above be sure cap is raised sufficiently above main pipe to allow flue gases to vent unimpeded 3 popular type cap is shown in B 4 The tee is frequently used as shown in C 5 D and E should not be used due to possible fluctuations in back pressure Figure 3b Vents Faults and Suggestions WARNING Venting Instructions are recommendations only Consult a venting expert on the design of a specific vent system for your application The ASHRAE Venting Guide and The National Fuel Gas Code NFPA 54 should be considered in all venting systems Conventional vent material may not be suitable for the application Flue gases can leak carbon monoxide from the joints on these materials and can result in severe personal injury or death Installations having long horizontal runs or an excessive amount of tees or elbows will restrict the flow of combustion gases and can result in condensation flue gas leakage of carbon monoxide resulting in severe personal injury or death SECTION Il CAST IRON BLOCK ASSEMBLY INSTRUCTIONS Knockdown Boilers NOTE Only factory pa
131. sembly gt 2414 Rod 3734 Rod 4412 Rod 2414 Rod Nut 27 Rod 24 4 Rod Nut 34 Rod 31 Rod Nut 34 Rod 37 4 Rod Nut 34 Rod 44V Rod Nut 34 Rod 24 4 Rod Nut 27 Rod Nut 34 Rod 31 Rod Nut 27 Rod Nut 34 Rod 3734 Rod Nut 27 Rod Nut 34 Rod 44V Rod Nut 27 Rod Nut 34 Rod 44V Rod Nut 34 Rod Nut 34 Rod 31 Rod Nut 27 Rod Nut 27 Rod Nut 34 Rod 2 ASSEMBLY OF SECTIONS HYDRAULIC DRAW UP e MPC4 through MPCI2 Section Assemblies The entire assemblage may be drawn up at one time using the hydraulic draw up equipment providing the operation is completed within two 2 hours after the sealant was applied to the first casting in the assembly If time limit 15 reached draw up partial section assembly before continuing MPC13 through MPC18 Section Assemblies The total assemblage should be first drawn up into two 2 sub assemblies Each sub assembly may be drawn up at one time using the hydraulic draw up equipment providing the operation is completed within two 2 hours after the sealant was applied to the first casting in the sub assembly No more than 12 sections should be drawn up at one time Hydraulic Draw Up Tool Kit is available through Burnham by ordering part number 101904 01 Step a Repeat Step through Step under Field Assembled Sections Manual Draw Up Step b Continue driving sections
132. signed for negative pressure is acceptable When an MPC oil fired or combination gas oil fired boiler is connected to a venting system that is designed so that it will operate under a negative pressure the use of Type L or other manufactured vent systems designed for negative pressure is acceptable Unlined masonry chimneys are not acceptable Lined masonry chimneys are acceptable with the appropriate vent connectors using materials described above MPC oil or combination gas oil boilers should be vented using Type L vent regardless if the vent pressure is positive or negative 15 WARNING Single wall Type C vent material is not approved for MPC boiler venting When an MPC gas fired boiler is connected to a venting system that is designed so that it will operate under a negative pressure manufactured vent systems designed and approved for positive pressure application per UL1738 must be used for example Van Packer Model CS Protech Model FasNSeal FasNSeal W2 Heatfab Saf T Vent or equivalent When an MPC oil fired or combination gas oil fired boiler is connected to a venting system that is designed so that it will operate under a positive pressure manufactured vent systems designed and approved for positive pressure application must be used for example Selkirk Metalbestos Model PS IPS Van Packer Model ES or equivalent RAIN CAP RIGHT TEE TYPE 90 ELBOW UP or DOWN VENT SIZING Area must be the same a
133. smooth excess sealant over joint with your finger WARNING Sealant must be properly applied to ALL boiler joints Failure to properly seal the boiler joints will result in combustion gas leaks through the joint DO NOT operate boiler with combustion gas leaks 7 10 11 f Install observation port sight glass Locate 2 x 2 1 2 12 nipple sight glass envelope and 2 conduit bushing Thread 2 nipple into observation port tapping directly above burner adapter opening on front of BSD Open sight glass envelope and in this order place gasket sight glass and gasket into conduit cap Thread cap unto 2 nipple hand tighten only until cap and glass are snug Do not over tighten g Do not install BSD on hinges at this time Door must be installed after jacket assembly Mount C I flue collector to rear section see Figure 9 a Usea wire brush to clean the rope groove on back surface of rear section b Using the multi purpose spray adhesive provided apply the adhesive to the perimeter rope groove Follow the directions on the can for application and tack time c Locate remaining 158 length of silicone coated fiberglass rope from common parts carton Starting at 3 o clock position push rope into groove and continue around perimeter until rope overlaps the starting point Rope should be approximately 4 longer than required Use a permanent black marker to mark the rope approximately 1 8 beyond point of ov
134. st once a year See Section V Paragraph E under Operating Instructions for control checks See Burner Manual and Table XII for recommended burner tests and adjustments LUBRICATE BOILER COMPONENTS according to manufacturer s instructions Generally this involves the burner and circulator This includes the type of lubricant to use frequency of lubrication and points to lubricate GENERAL MAINTENANCE CONSIDERATIONS 1 Keep radiators and convectors clean 2 If a hot water radiator is hot at the bottom but not at the top it indicates that air has accumulated inside and should be vented To vent radiator hold small cup under air vent located near top of radiator open vent until water escapes and then close 3 If alarge volume of water is added to the system it 15 advisable to heat the system to high temperature and vent again This will make less venting necessary during the winter 4 Where an expansion tank is used make sure that neither the tank nor its drain pipe is exposed to freezing temperatures Never place valves in piping leading to or from expansion tank 5 Boiler and system cleaning will help assure trouble free operation See Section V Paragraph F under Operating Instructions for procedure ATTENTION TO BOILER WHILE NOT IN OPERATION WARNING If boiler is not used during winter time it must be fully drained to prevent freeze damage 1 Spray inside surfaces with light lubricating or c
135. t zZz zZz 3 zZz zZz zZz z z jeoeds 67 26 18 0 AI 91 Z X QO 91 1 9 20 9660 Z 2 2 Z 2 2 2 Z Z 2 2 2 Z 2 67 9 6 6 X91 8 v 1201S EJAN 19945 81009808 21 Cee e SEM 61 21 E 1028 00 2 Z 2 Z Z 2 2 2 Z Z 2 c 2 4 10 897001 fo ok ie uoddng oque 8 2 9 SL Zi OF 60 80 20 90 80 v0 donasse ON AlaWwassv 5 HV3H SLYVd HIVd3H 85 86 K BLOCK ASSEMBLY Figure 59 MPC Return Water Mixing Tube RC Assembly CQ co co co st 3 TO 59411 16101 7 82 20 88 201 L L 8 8 2 2 2 2 8 1 22 81 91 1 82 91 S 12 81 10 88 201 0 88 201 20 22100 L0 22Z001 10 06 201 55 OU AENL ONIXIN H31VM NYNLAY HIVd3H NON 91 61 21 10 68 201 8LOdW ZLOdW 9LOdW VLOdW ELOdW OLOdW 69dlIN 89dIN LOdN 924 SOdN vOdN 87 WRAPPER ONE PIECE COMPLETE INSULATION WRAPPER
136. t tie bar on a slight angle and pass the end through opening in rear bracket as shown in Figure 22 Step b Lower the tie bar between brackets as shown in Figure 22 Step c Pull tie bar back and engage opposite end through opening in front or center section bracket as shown in Figure 22 Step d Engage slotted end of hook over lip of opening and push downward to lock position If necessary spread brackets by pushing or pulling vertical channels until tie bar drops into locking position see Detail A in Figure 22 For multiple tie bars each consecutive bar must be rotated end for end so the top flanges oppose each other for entry into opening see Detail B in Figure 22 Complete process to front bracket and repeat on opposite side LY TOP BRACKET HOLES SLIT TO EDGE S 1 4 SUPPLY MANIFOLD HOLE SLIT AAS AN WRAPPER AA TO EDGE BLOCK ASSEMBLY W HINGE FRAME RAILS INSTALLED POCKETS LOWER BRACKET ONE PIECE INSULATION WRAPPER SLITS 4 THRU 6 SECTION BLOCK SUPPLY MANIFOLD REAR WRAPPER CENTER WRAPPER LOWER BRACKET LOWER SLITS BRACKET NOTCH MODULAR INSULATION WRAPPERS 7 THRU 18 SECTION BLOCK Figure 23 Heat Exchanger Insulation One Piece and Modula
137. te L4006A Low High Low Control and remove knockout on casing closest to mounting hole Connect end of harness with forked terminals to casing knockout Connect black and gray wires to terminals on Low High Low Control wires are interchangeable Refer to Figure 44 iii Connect opposite end of LA006A Low High Low Control harness to junction box cover A hole location 4 as shown in Figure 40 iv Locate mating connector labeled LO HI LO MOD inside right junction box Join mating connectors which are polarized and lock together Lightly tug on connectors to make sure they are secure Proceed to next appropriate control option listed below for installation details If no other controls are being installed at this time secure Cover A and Cover to jacket rear top panel with two 2 8 x 1 2 gt LOW FIRE HOLD Bo 7 CONTROL HARNESS lg hex head SMS per cover Install 7 8 knockout plugs provided to all unused holes refer to Figure 40 b Install Modulating Control as follows i Apply thread sealant to 3 4 immersion well and install in Tapping as shown in Figure 38 Wrench well until water tight ii Locate T991A Modulation control and remove knockout on casing closest to temperature control knob Connect end of harness with forked terminals to casing knockout LOW HIGH LOW CONTROL a HARNESS 24 2 CN V 1027 L4006A we Sa LO
138. th two 2 8 x gt lg SMS see Figure 26 order of assembly shown in Table X also refer to Detail A If necessary push or pull frame rails to illustration in Figure 26 align holes Step 1 On 4 thru 6 Section Boilers assemble top NOTE Like the lower tie bars installed corner panel 1 to 6 top corner panel 2 using previously these top corner panels two 2 8 x gt Ig hex head sheet metal screws maintain the proper distance between before installing on frame rails as noted in Step 2 frame rails for assembly of remaining Step 2 Starting on the left side at the front secure jacket panels top corner panel 1 to front horizontal and vertical Step 4 On 7 thru 11 Section Boilers locate top corner frame rails with two 2 8 x lg hex head sheet panel 2 per Table X and secure to panel 1 using metal screws SMS two 2 8 1 2 Ig hex head SMS Align mounting holes in panel 2 with holes in frame rails and secure with two 2 8 x 12 lg hex head SMS Table X Jacket Top Corner Intermediate Panel Arrangement Side of Order of Assembly See Panel Designation Below Boiler Front Block Assembly gt 27 TCP w J 6 TCP w H 4 Section 6 TCP w H 27 TCP wid 33 TCP wid 6 TCP 6 33 TCP w J 40 TCP wid 6 TCP w H 6 TCP w H 40V TCP w J 3394 TCP wid 27 TCP mum 33 TCP wid 33 TCP w H 33 TCP w H 33 TCP w J 33
139. to openings at bottom of flue collector Locate four 4 5 16 flat washers and four 4 5 16 18 x 7 8 lg cap screws from hardware bag Thread 1 washer and screw into left j tapping on each opening Engage slot on clean out cover behind washer Thread second screw with 1 279 washer through slot and into tapping on opposite end 7 1 Wrench tighten hardware securely See Figure 9 1 uU J Locate and Install Blank Sensor J Box Cover over opening in Jacket Right Split Rear Panel as shown in A 6 8 X 1 2 LG HEX 5 P J 5 5 Figure 28 Secure cover with two 2 8 x 2 lg hex head SMS 2 Locate Jacket Top Panel Carton marked JC 3 and remove contents Starting in the front install jacket front top panel first and then add consecutive panel s as outlined in Table XI working toward the rear of block assembly 27 TOP CORNER PANEL REAR FRAME RAIL __ JACKET SPLIT REAR PANEL JACKET SPLIT REAR A tL PANEL REAR FRAME RAIL E 4 RECTANGULAR HOLE gt ed LOCKING HOOK LOCKING n gt HOOK n L DETAIL Figure 29 Install Jacket Split Rear Panel 45 Table Jacket Top Panel Arrangement Boiler Order of Assembly Size Front Block Assembly gt 6 Section 3577 Front Top Panel 7 Section 20
140. trical burner The burner may remain attached to the power to the boiler must be off BSD during cleaning if CLEAN THE BOILER HEATING SURFACES i enough space exists for the BSD to swing AND FLUE at least once each year preferably at the open completely with the burner still end of the heating season attached 1 CLEAN THE VENT SYSTEM Vent system should and the burner weight is supported by a be checked annually for suitable prop at all times a Obstructions b Remove optional BSD cover panels if b Accumulations of soot provided c Remove four 4 9 16 cap screws and lock washers from the hinge pockets on the BSD d Open the BSD and remove the baffles from all flue passages c Deterioration of vent pipe or vent accessories due to condensation or other reasons d Proper support no sags particularly in horizontal runs 4 e Usea wire or fiber bristle brush to remove accumulated soot or debris from all of the flue baffles e Tightness of joints Use a wire or fiber bristle brush of appropriate length and diameter to allow sufficient cleaning of all flue passages Using long strokes push the brush the whole way through the boiler and then pull it out Repeat this process until all surfaces of each of the flue passages have been cleared of all soot and debris Vacuum all loose debris that has collected in the rear of the combustion chamber and in the turnaround passages into the second flu
141. ty ceases upon delivery of crated Boiler to the carrier in good condition 2 ANY CLAIMS for damage or shortage in shipment must be filed immediately against the carrier by the consignee No claims for variances from or shortage in orders will be allowed by the manufacturer unless presented within thirty 30 days after the receipt of goods B LOCATE THE UNIT Recommended clearance for service may be reduced to minimum clearance to combustible material However increased service and maintenance difficulty will result 1 RECOMMENDED SERVICE CLEARANCE Locate the unit in the boiler room so as to provide ease of venting and adequate clearance for maintenance serviceability and installation of piping Refer to Figure 1b and Table 1 for boiler dimensional data From Jacket Front Panel e Provide 54 service clearance for removal maintenance and servicing of burner and controls e Provide service clearance for removal of baffles to perform annual cleaning of flueways refer to Table I Dimension From Jacket Rear Panel e Provide a minimum service clearance from the boiler jacket for access to boiler supply and return piping relief valve drain valve flue collector clean out covers vent piping and optional flue damper assembly See Table III Table Ill Recommended Rear Service Clearance Combustible or Non Combustible Surfaces Flue Outlet Size From Jacket Left Side Panel Pro
142. ty of the glycol solution is usually higher than water requiring a higher pump head for the same given flow Consult factory for specific applications pump selection and flow rate If this boiler is used in connection with refriger ation systems the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler See Figure 53 OOLING Figure 53 Recommended Piping for Combination 63 NOTICE When possible domestic hot water production should utilize dedicated boiler s This will allow the other boiler s to be shut down and isolated during the summer months If the boiler load is shared between heating and domestic hot water then one needs to determine if a hot water priority is required If a priority is not selected erratic domestic hot water production may result during the beginning and end of every heating season Conversely a priority for domestic hot water production may cause a significant heating zone activation delay in an improperly balanced system Parallel piping conversions may require isolation from the heating system to prevent system flow influence on DHW performance Consult a qualified system heating professional to design for the proper application BOILER PIPING DOMESTIC HOT WATER DHW APPLICATION The MPC boiler can be used in many different piping applications to produce Domesti
143. ue Carton Req d Per Boiler Size Component Description Designation Pat Number 5 8 oio Code Label 1 5 0 1 11 1 090 Parts Cartons Continued 07 Lows Dose mete Heat esos 1 7 EU co pre I ELIT 8 erwe ooe E T Trews pos 21001110 111101 Pear Heat Tarawa 1 0 ems 111110 11111 11 Center Heat Exchanger mm el lll Insulation Wrapper 2 _ i 27 24 10183741 eee a a e 26 101837 06 1 Jc27 10183707 ces 101837 08 29 10183709 Jacket Uncommon Panels Jc2 10 10183710 eesi E el lT m m Heat Exchanger Insulation Bags Internal Wiring Harness sc2 12 10183712 10 827431 1 _ 89 51 xo 10175 Jacket Pane 10827481 oo 18 81 Boiler 4 sos see _ 7 10183807 46 8 10188881 cao 10188809
144. ue clean out covers and burner are all secured in place C MAINTENANCE OF LOW WATER CUTOFF DEVICES NOTICE Probe and float type low water cutoff devices require annual inspection and maintenance 1 PROBE TYPE LOW WATER CUTOFF Although these devices are solid state in their operation the probe is exposed to possible contamination in the boiler water and subject to fouling It is important to physically remove the probe from the boiler tapping annually and inspect that probe for accumulation of scale or sediment Follow these steps to inspect clean and or replace the probe a Turn off electric service to the boiler b Close isolation valves in supply and return near boiler piping c Drain boiler water to a level below the tapping for the probe d Disconnect wiring connections between the low water cutoff control and the probe DANGER Assure that the boiler is at zero pressure before removing the LWCO probe Do not rely on the pressure gauge to indicate that the boiler is at zero pressure Open the relief valve to relieve all internal pressure prior to proceeding Relief valve discharge piping must be piped such that the potential for burns is eliminated e Dismount the low water cutoff control from the probe f Unscrew the probe from the boiler tapping g Inspect that portion of the probe that is exposed Do not overtighten The rope gasket will provide sufficient seal when the door is snugged
145. ure 27 Detail A Rotate bottom of front panel until locking tabs rest against vertical frame rails On one side only flex side of panel until hooks clear face of vertical rail Align top and bottom hooks with slotted holes nearest front edge Engage both hooks and allow panel to drop down to lock in place Repeat for opposite side Note Before installing rear panel drain valve and indirect water heater return piping furnished by others should be installed now due to accessibility Rear panel is shipped loose in two 2 halves see Figure 28 As viewed from rear of boiler install left split rear panel first Install panel by tilting on a slight angle to engage top flange behind bottom flange on jacket top corner panel see Figure 29 Detail A Rotate bottom of left rear panel until locking tabs rest against OFF SET FLANGE E d vertical frame rail flex side of panel until hooks clear COVER PLATE face of vertical rail Align top and bottom hooks with LEFT SPLIT 221 rectangular holes nearest rear edge Engage both hooks and allow panel to drop down to lock in place J as uate HEK see Figure 29 Repeat same procedure to install jacket right split rear panel making sure that right side panel overlaps offset flange on left side panel Secure panel seam with six 8 x gt 1g hex head SMS as shown RIGHT SPLIT 1 1 MT in Figure 28 I Install two 2 clean out covers
146. ure in ram pumps and then move clamps to new position Step e Continue to draw up until all sections make contact at the ground joints If the sections still do not appear to be drawn metal to metal use feeler gauge provided to measure any gaps at the locations identified in Figure 8 Unless specified otherwise gaps should be measured at these locations A maximum gap of 025 is acceptable 23 24 Step f After all sections have been drawn retention rods must be installed Do not release hydraulic pressure until the retention rods are in place Step g Locate the threaded 5 8 retention rods washers tension springs and nuts supplied in BAC Boiler Assembly Carton Assemble both top retention rod assemblies as shown in Figure 5 Detail B using the proper arrangement per Table VI The tension spring should always be located at the rear of the boiler These rod assemblies can be lowered directly into slotted lugs on each side of the upper nipple port Hand tighten the rear nuts only do not torque nut at this time All casting legs have two 2 holes Slide the lower retention rods through the upper hole in each leg Start the front or rear which ever is easiest per the arrangement shown in Table VI With the rods in place install a 5 8 flat washer and 5 8 hex nut on each rod protruding through the front legs On 8 through 18 section block assemblies additional rods and couplings nuts are required to sp
147. used by improper fuels fuel additives or contaminated combustion air that may cause fireside corrosion and or clogging of the burner or heat exchanger i Any damage resulting from combustion air contaminated with particulate which cause clogging of the burner or combustion chamber including but not limited to sheetrock or plasterboard particles dirt and dust particulate j Any damage defects or malfunctions resulting from improper operation maintenance misuse abuse accident negligence including but not limited to operation with insufficient water flow improper water level improper water chemistry or damage from freezing k Any damage caused by water side clogging due to dirty systems or corrosion products from the system Any damage resulting from natural disaster m Damage or malfunction due to the lack of required maintenance outlined in the Installation and Operating Manuals furnished with the unit 6 Exclusive Remedy Burnham Commercial obligation for any breach of these warranties is limited to the repair or replacement of its parts not including labor in accordance with the terms and conditions of these warranties 7 Limitation of Damages Under no circumstances shall Burnham Commercial be liable for incidental indirect special or consequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss
148. ust be filed immediately against the carrier by the consignee No claims for variances or shortages will be allowed by Boiler Manufacturer unless presented within thirty 30 days after receipt of equipment IMPORTANT INFORMATION READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE All boilers must be installed in accordance with National State and Local Plumbing Heating and Elec trical Codes and the regulations of the serving utilities These Codes and Regulations may differ from this instruction manual Authorities having jurisdiction should be consulted before installations are made In all cases reference should be made to the following Standards USA BOILERS A Current Edition of American National Standard ANSI NFPA 31 Installation of Oil Burning Equipment for recommended installation practices B Current Edition of National Fuel Gas Code NFPA 54 ANSI Z223 1 C Current Edition of American National Standard ANSUNFPA 211 Chimneys Fireplaces Vents and Solid Fuel Burning Appliances for venting requirements D Current Edition of American Society of Mechanical Engineers ASME CSD 1 Controls and Safety Devices for Automatically Fired Boilers for assembly and operations of controls and safety devices E wiring on boilers installed the USA shall be made in accordance with the National Electrical Code and or Local Regulations CANADIAN BOILERS A Current Edition of Canadian Standards Association CSA B139 Install
149. ve s Check safety shutdown timing Record in Log If flame signal meter installed read and log For both pilot and main flames notify service organization if readings are very high very low or fluctuating Refer to burner instruc tions Operator Service Technician Required after any adjustments to flame scanner mount or pilot burner Verify annually Refer to burner instructions Hot Refractory Hold In As required annually See Pilot Turndown Tests Low Water Cutoff and Alarm Daily Weekly Semiannually Refer to instructions Perform a slow drain test in accor dance with ASME Boiler and Pres sure Vessel Code Section VI Operator Operator continued 71 72 Table Recommended Periodic Testing Check List continued High Limit Safety Control Annually Refer to instructions Operating Control Annually Refer to instructions Low Draft Fan Air Monthly Operator Refer to burner instructions Pressure and Damper Position Interlocks High and Low Gas Monthly Operator Refer to burner instructions Pressure Interlocks High and Low Oil Monthly Operator Refer to burner instructions Pressure Interlocks High and Low Oil Monthly Operator Refer to burner instructions Temperature Interlocks Fuel Valve Interlock Annually Refer to burner instructions Switch Purge Switch Annually Refer to burner instructions to burner instructions Burner Position Interlock Annually E to burner instructions
150. vide clearance per Table I Dimension B for burner swing door BSD opened fully with burner mounted otherwise 12 with burner removed 18 access clearance to service rear of boiler if right side clearance is less than 12 12 minimum if right side clearance is 18 or larger to access and service rear of boiler From Jacket Right Side Panel See Table I Dimension B if BSD is hinged to swing to right side with burner mounted otherwise 12 minimum if left side clearance is 18 or larger to access and service rear of boiler From Jacket Top Panel Provide a minimum clearance from the boiler jacket of 24 2 FOR MINIMUM CLEARANCES to combustible materials See Table IV or Table V Table IV Minimum Installation Clearances To Combustible Materials Inches per ANSI NFPA 31 Knockdown Non UL Packaged Boiler 4 C i we c FRONT x SIDE Ip OF BOILER BOILER fb D C B Chimney D E Boiler Above Front Connector Rear Sides MPC 24 18 6 6 Note See Table for recommended service clearance to access rear of boiler NOTE 1 Listed clearances comply with American National Standard ANSI NFPA 31 Installation of Oil Burning Equipment NOTE 2 MPC Series boilers can be installed in rooms with clearances from combustible material as listed above Listed clearances cannot be reduced for alcove or closet installation
151. will cause corrosion of iron and steel boiler components and can lead to boiler failure 5 Boileris now ready to be put into service Burnham s standard warranty does not cover G FREQUENT WATER ADDITION problems caused by oxygen contamination of boiler water or scale lime build up caused by frequent addition of water IMPORTANT IF DURING NORMAL OPERATION IT IS NECES TEE aE MARS SARY TO ADD WATER MORE FREQUENTLY HUE THAN ONCE MONTH CONSULT QUALIFIED SERVICE TECHNICIAN TO CHECK YOUR SYSTEM FOR LEAKS a Addition of excessive make up water as a result of system leaks b Absorption through open tanks and fittings A leaky system will increase the volume of make up c Oxygen permeable materials in the distribution water supplied to the boiler which can significantly shorten the life of the boiler Entrained in make up d Suction at pump and valve seals water are dissolved minerals and oxygen When the In order to ensure long product life oxygen sources fresh cool make up water is heated in the boiler the should be eliminated This can be accomplished by minerals fall out as sediment and the oxygen escapes taking the following measures as a gas Both can result in reduced boiler life The a Repairing system leaks to eliminate the need for accumulation of sediment can eventually isolate addition of make up water the water from contacting the cast iron When th
152. y develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention Lift door high enough to move hinge pockets through opening in jacket front panel Engage hinge loop attached to door over hinge pin attached to block assembly Lower door to rest weight on hinge pin brackets Locate Flueway Carton s marked 2 and and remove contents Check Equipment Check List for proper baffle length and usage per boiler size On4 thru 11 Section Boilers Install four 4 third pass baffles into third pass flueways until handle is flush with face of casting as shown in Figure 32 Detail A ard PASS FLUEWAY 7 BAFFLE 4 REQ D FRONT SECTION 2 4 thru 18 Section Boilers Install four 4 second pass baffles into second pass flueways until handle 18 flush with face of casting as shown in Figure 33 Detail A FACE OF FRONT CASTING BAFFLE HANDLE TO BE FLUSH 8rd PASS FLUEWAY BAFFLE INSTALLED SEE DETAIL Figure 32 Install 35 Pass Flueway Baffles 4 thru 11 Section Boilers Only BAFFLE HANDLE _ TO BE FLUSH 2nd PASS FLUEWAY BAFFLE 4 REQ D FRONT SECTION FACE OF DETAIL 2nd PASS FLUEWA

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