Table of Contents
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- 1 Important Information
- 2 Section II - Cast Iron Block Assembly Instructions (Knockdown Boiler)
- 3 Install Common Parts to Block (Hinge Hardware, Flue Collector, Clean-Out Covers, Etc.)
- 4 Install Flue Outlet Damper Assembly
- 5 Boiler Piping - Heating Applications
- 6 Section IV - Installation Instructions
- 7 Section V - Operating Instructions
- 8 Test Controls
- Download this manual
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Commercial Boilers
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Price - $5.00
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Table of Contents
Related Manuals for Burnham MPC
Summary of Contents for Burnham MPC
- Page 1 ™ 3050579 Commercial Boilers www.burnhamcommercialcastiron.com 101786-01R5-11/10 Price - $5.00...
- Page 2 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 the Installer can determine if all parts have been provided for the boiler ordered. It covers standard equipment for Knockdown boilers, 4 thru 18 section models. Optional equipment ordered will be in addition to, or in lieu of, equipment shown below. To simplify boiler assembly, instructions refer to carton designations located in box on Bar Code Labels, see Figure 1a. When instructed, locate and open specified carton. Some cartons use all contents immediately and others use Figure 1a: Carton Identification parts throughout the assembly procedure until depleted. KNOCKDOWN BOILER - EQUIPMENT CHECK LIST Qty.
- Page 3 KNOCKDOWN BOILER - EQUIPMENT CHECK LIST (Continued) Qty. Req’d. Per Boiler Size Carton Designation Part Component Description on Bar Number Code Label Parts Cartons (Continued) CPHW 4 101835-04 1 Complete Heat Exchanger CPHW 5 101835-05 Insulation Wrapper CPHW 6 101835-06 FTHW 1 101849-01 Front Heat Exchanger...
- Page 4 KNOCKDOWN BOILER - EQUIPMENT CHECK LIST (Continued) Qty. Req’d. Per Boiler Size Carton Designation Part Component Description on Bar Number Code Label Parts Cartons (Continued) JC4- 4 101839-04 1 JC4- 5 101839-05 JC4- 6 101839-06 JC4- 7 101839-07 JC4- 8 101839-08 JC4- 9 101839-09...
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Page 5: Important Information
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. - Page 6 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.
- Page 7 It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler MAWP. Therefore, Burnham offers safety relief valves set at or below the MAWP of the boiler. See Page 1 for available safety relief valve set pressures.
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Page 8: Table Of Contents
TABLE OF CONTENTS SECTION I - GENERAL INFORMATION Dimensional Information ......................... 10 Ratings/Data ............................1 Locating the Unit ..........................1 Air Supply/Venting ..........................1 SECTION II - CAST IRON BLOCK ASSEMBLY INSTRUCTIONS (Knockdown Boiler) Knockdown Boiler w/ Factory Assembled Section ................ 17 Assembly of Sections, Manual Draw-up .................. - Page 9 TABLE OF CONTENTS (continued) SECTION VI - SERVICE INSTRUCTIONS Cleaning Boiler Heating Surfaces ....................68 Maintenance of Low Water Cutoff Devices ..................69 Checking Burner & Controls ......................70 Lubrication ............................70 General Maintenance Considerations ..................... 70 Attention to Boiler While Not in Operation ..................70 Recommended Periodic Testing ......................
- Page 12 TABLE II: RATINGS/DATA Model MPC™ Boilers (4) Combustion Burner Input Efficiency MPC4 12.7 3.55 89.0 86.3 75.0 0.10 2820 MPC5 19.5 5.50 88.8 86.1 95.3 0.19 3396 MPC6 25.0 7.10 88.7 86.0 115.5 11.0 0.28 3972 MPC7 30.6 8.70 1218 1216 1023 88.7 86.0...
- Page 13 SECTION I - GENERAL INFORMATION (Continued) from Jacket Left side Panel: INSPECT SHIPMENT carefully for any signs of damage. • Provide clearance per Table I, Dimension ‘B’, for burner swing door (BSD), opened 1. ALL EQUIPMENT is carefully manufactured, fully with burner mounted, otherwise 12” inspected and packed. Our responsibility ceases with burner removed. upon delivery of crated Boiler to the carrier in good • 18” access clearance to service rear of boiler condition. if right side clearance is less than 12”. 2. A NY CLAIMS for damage or shortage in shipment must be filed immediately against the carrier by • 12” minimum if right side clearance is 18” or larger to access and service rear of boiler. the consignee. No claims for variances from, from Jacket Right side Panel: or shortage in orders, will be allowed by the manufacturer unless presented within thirty (30)
- Page 14 Table V: Minimum Installation Clearances To WARNING Combustible Materials (Inches) per UL76 (Packaged / Firetested Boiler) All 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).
- Page 15 a. In the absence of local requirements, the confined space shall be provided with two permanent openings, one in or near the top of the room and one near the bottom. The openings shall communicate by means of ducts, with the 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. in. per 2,000 Btuh (70 sq. in. per 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 MPC™ Series boiler is designed for forced draft firing and may be used with a conventional natural draft stack (15’ minimum Figure a: MPC with Rear Outlet Vent height) or a stub vent, sometimes called a diesel...
- Page 16 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 UL178, must be used (for example, Van-Packer Model CS, Protech Model FasNSeal / FasNSeal W, Heatfab Saf-T-Vent or equivalent).
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Page 17: Section Ii - Cast Iron Block Assembly Instructions (Knockdown Boiler)
SECTION II - CAST IRON BLOCK ASSEMBLY INSTRUCTIONS (Knockdown Boilers) NOTE: Only factory packaged and firetested units are eligible to bear the UL listing mark. outlined in Section I. Lifting arrangement and weights FACTORY ASSEMBLED SECTIONS - The are given in Figures 4a and 4b. assemblage should be set in the proper location as Lifting Lift Locations Number of Weight Sections (lbs) Hooks 1 & 2 Hooks 3 &... -
Page 18: Assembly Of Sections, Manual Draw-Up
WARNING These sections are designed to be drawn together one section at a time using the Manual Draw-up Kit Sealant must be properly applied to ALL boiler (Burnham P/N 102008-01 or P/N 102008-02) using joints. Failure to properly seal the boiler joints ordinary hand tools. will result in combustion gas leaks through the Tools required: joint. DO NOT operate boiler with combustion (1) ¾” Drive Ratchet... - Page 20 Figure 6: Vertical Bracing of Rear Section Figure 7: Setting of Nipples Figure 8: Inspection Pad Locations for Section Draw-up...
- Page 21 This is a forced draft fired boiler and sealant must be approximately 3/8” to 1/2” apart. The 7” be applied where specified for proper and safe nipple will pull harder than the 3” nipple. If performance. Burnham Commercial has approved two (2) people are pulling simultaneously, section joint sealants (silastics) manufactured stop periodically to verify that gaps between by Dow-Corning under the product number RTV...
- Page 22 adjacent sections as the boiler operates with a All casting legs have two (2) holes. Slide the positive pressure in the firebox and products of lower retention rods through the upper hole in combustion will escape between sections unless each leg. Start at the front or rear, which ever is they are properly sealed. The rope and sealant easiest, per the arrangement shown in Table VI. With the rods in place, install a 5/8” flat washer should be applied before each section is placed on the assembly. and 5/8” hex nut on each rod protruding through the front legs. On 8 through 18 section block NOTICE assemblies, additional rods and couplings nuts are required to span the distance. On these larger As assembled length increases, use /” coupling sizes, thread couplings on front rods to mid point nuts and additional rods, provided in Kit, to extend of coupling (halfway), pull next rod forward to draw-up rod length.
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Page 23: Assembly Of Sections, Hydraulic Draw-Up
No more than Refer to Figure 5 to verify proper arrangement. 12 sections should be drawn up at one time. “Hydraulic Draw-Up Tool Kit” is available through CAUTION Burnham by ordering part number 101904-01. Rods should be approximately centered in Step a. Repeat Step ‘a’ through Step ‘l’ under openings so that rods and couplings (when “Field Assembled Sections (Manual Draw-Up)”. - Page 24 step f. After all sections have been drawn up, Excess length of draw-up rods must not extend beyond front and rear section to ensure proper fit retention rods must be installed. Do not release hydraulic pressure until the retention rods are in of jacket, adjust accordingly. place. step h. Release tension on hydraulic pumps and step g. Locate the threaded 5/8” retention rods, rams and remove. washers, tension springs and nuts supplied in HYDROSTATIC TEST - After the boiler sections ‘BAC’ Boiler Assembly Carton. Assemble both have been assembled, it is essential that the boiler top retention rod assemblies as shown in Figure be hydrostatically tested before the jacket frame, 5, Detail B, using the proper arrangement per insulation, internal wiring, piping or jacket is installed. Table VI. The tension spring should always THIS TEST IS AN ASME CODE REQUIREMENT. be located at the rear of the boiler. These rod 1. Block Assembly must be free of air, provide valve in assemblies can be lowered directly into slotted 4” bushing on top supply tapping to purge air during lugs on each side of the upper nipple port. Hand the filling process. Plug all boiler tappings and fill tighten the rear nuts only, do not torque nut at this time.
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Page 26: Section Iii - Boiler Assembly Instructions (Knockdown Boiler)
For the purpose of these instructions, Burnham will default to mounting hinge set for left hand swing (left side). -
Page 27: Install Return Water Mixing Tube
f. Install observation port sight glass. Locate 2” b. Apply thread sealing compound to both ends x 2-1/2” lg. nipple, sight glass envelope and of the 4” NPT nipple and install one end of the 4” NPT nipple into the non-flow arrowed end 2” conduit bushing. Thread 2” nipple into observation port tapping directly above burner of the CI Supply Manifold and hand tighten the adapter opening on front of BSD. Open sight assembly. glass envelope and in this order place gasket, c. Then - Install the threaded end of the 4” NPT sight glass and gasket into conduit cap. Thread nipple into 4” NPT tapping located on top of rear cap unto 2” nipple, hand tighten only until cap section. and glass are snug. Do not over tighten. d. Wrench - CI Supply Manifold Assembly until g. Do not install BSD on hinges at this time. Door water tight and 1½” NPT tappings (relief valve) must be installed after jacket assembly. are aligned with front and rear axis as shown in 7. Mount C. I. flue collector to rear section - Figure 12. -
Page 30: Install Jacket Support Frame To Block
Repeat this process for each joint, securing the 6. Thread upper and lower positioning plugs into 1/2” previous assembly to the tube shown 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, tapping on upper front section boss. into the 4” NPT tapping on the back of the rear a. Looking through 3” tapped hole, check position section before joining the remaining tube(s). Allow of support collar on RWMT end cap. Collar approximately 1½” of the tube to protrude from should be located approximately in the center of the tapping, so that the next tube can be secured to the tapped hole both vertically and horizontally. the assembly. Once the next tube is secured, insert b. If necessary, adjust support collar position before the assembly further into the tapping. Repeat this installing front support plug. For horizontal procedure as necessary for up to seven (7) tube adjustment, bend support clip up or down per the RWMT assemblies. - Page 31 one (1) 2-5/8” lg. spacer, two (2) washers and one (1) hex nut on the opposite end of rod. Repeat for second bracket, refer to assembled end view in Figure 17b. 7. Mount front/center horizontal channel assembly(lies) to appropriate casting(s) on block assembly as outlined in Table VIII. 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. 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 into slotted openings on both castings as shown in Figure 16: Secure Brackets to Horizontal Channel Figure 18b, Detail A. Hand tighten nuts, make sure 5. Add front/center section mounting hardware to all washers engage casting below washer retaining lugs but one (1) horizontal support channel assembly. as shown in Detail B. Repeat for opposite side. Lay channel assembly on floor with brackets facing 9. Wrench tighten hex nuts on all channel assemblies up, see Figure 17a. Install hardware as shown making sure rods are fully seated in slotted...
- Page 32 Figure 17a: Front/Center Section Horizontal Channel Assembly w/Mounting Hardware Figure 17b: Rear Section Horizontal Channel Assembly w/Mounting Hardware...
- Page 33 Figure 18a: Mount Front/Center Section Horizontal Channel to Block Assembly Figure 18b: Mount Rear Section Horizontal Channel to Block Assembly...
- Page 34 Figure 19: Attachment of Lower Front/Center Section Bracket to Casting Leg Figure 0: Attachment of Lower Rear Section Bracket to Casting Leg...
- Page 35 Hand tighten one (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, is located at the top, see Figure 21. Engage flanges front surface of leg with offset toward the rear as on vertical side channel over flanges on horizontal shown in Figure 20. Hold bracket at a 45° angle while engaging upper slot over threaded tie rod, channel and secure with two (2) #8 x 1/2 sheet metal screws. Engage vertical side channel flanges over rotate bracket around rod until lower slot is aligned with lower hole in casting leg. Insert 5/8 -11 x 2”...
- Page 36 Figure : Lower Tie Bar Installation step b. Lower the tie bar between brackets as Repeat operation until all vertical channels have been installed. Using an open end wrench and shown in Figure 22. ratchet with socket, tighten all 5/8” bolts and nuts to step c. Pull tie bar back and engage opposite end secure frame brackets to casting legs. through ‘I’ opening in front or center section 13. Locate Jacket Carton(s), marked ‘JC-2’ and remove bracket as shown in Figure 22. step d. Engage slotted end of hook over lip of ‘I’ contents. Install lower tie bars into slotted ‘I’ openings on lower frame brackets to provide proper opening and push downward to lock position. spacing between frame channels, refer to Figure 22. If necessary, spread brackets by pushing or Determine proper location of tie bar by comparing pulling vertical channels until tie bar drops into it’s length to the distance between brackets. Lay locking position, see Detail ‘A’ in Figure 22. For each tie bar on the floor at that location along both multiple tie bars, each consecutive bar must be rotated end for end so the top flanges oppose sides of boiler.
- Page 37 Figure : Heat Exchanger Insulation - One Piece and Modular Wrappers a. Rear Insulation Wrapper - Starting at the rear, Locate and Install Heat Exchanger (Block Assembly) drape rear wrapper over block assembly with Insulation Wrapper(s), see Figure 23. supply manifold hole facing the rear as shown 1. 4 thru 6 section Block Assembly - Insulation in Figure 23. Pull insulation under horizontal wrapper is provided as one-piece that covers block channel, open slits and pull insulation around from front to rear. Drape insulation wrapper over supply manifold and top brackets on each side. block assembly with supply manifold hole to the Pull both sides of insulation back between rear. Starting at top rear, pull insulation under vertical channel and rear casting. Open slit at horizontal channel, open slits and pull insulation bottom and position over lower rear bracket. around supply manifold and top brackets on each Tuck bottom edges behind lower tie bar. side. Pull both sides of insulation back between b. Center Insulation Wrapper(s) - 12 thru 18 vertical channel and rear casting. Open slit at Section Block Assembly.
- Page 38 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 ½” lg. hex 1. See Figure 24a for layout of Internal wiring harness head sheet metal screws, see Figure 24b. Install components. secondary junction box with extension piece to 2. Locate junction boxes shipped in Jacket Frame horizontal channel on right side of supply manifold Carton marked ‘JF’. As viewed from the rear, using two (2) #8 x ½” lg. sheet metal screws. Figure a: Internal Wiring Harness Components Figure b: Internal Wiring Harness Components - Mounting Junction Boxes...
- Page 39 3. Locate chaseway channel(s) shipped in Jacket Position channel extension under next horizontal Carton marked ‘JC-2’, see Figures 24c and 24d. rail, secure bracket on extension to previously Identify main chaseway channel by it’s unequal installed channel with two (2) #8 x ½” lg. hex head ends. Install the end with 8¼” lg. side flange under sheet metal screws. Torque these screws until horizontal rail and through openings in junction box tight. Secure front of channel extension to next until end protrudes past rear horizontal channel. horizontal rail with two (2) #8 x 2½” lg. sheet metal Secure main chaseway channel to both horizontal screws. Based on block size, repeat until chaseway frame rails using #8 x 2½” lg. hex head sheet metal extension has been secured to horizontal rail on screws as shown in Figure 24c. front section. NOTE: Torque screws through rear frame rail until 4. Install protective edging to raw edges of chaseway tight. At this time, only snug screws through channel(s) - Locate ‘JH-1’ Hardware Bag, packed forward rail(s) to allow movement in later assembly in JC-1 Jacket Carton. From raw stock provided steps when attaching jacket top corner panels. in Hardware Bag, cut two (2) pieces of protective edging 1-13/16” lg. and two (2) pieces 4-11/16” On 8 thru 18 sections block assemblies, install long.
- Page 40 Note: if sage Boiler control (sBc) is to be used Install 1-13/16” lg. pieces on horizontal raw edges with boiler, refer to installation section of sage at both ends of chaseway channel assembly. Install Boiler control instruction Manual (located in 4-11/16” lg. pieces to vertical chaseway channel flanges inside primary junction box as shown in sage Boiler control Parts carton) at this time. Review installation section of sBc manual in its Figure 24e.
- Page 41 Insert first set of harness connectors through Table IX: Internal Wiring Harness Adjustment opening in rear of secondary junction box. Remove Harness Adjustment excess slack between J-boxes until protective sleeve Boiler Wire Tie Wire Tie Wire Tie Wire Tie is centered on raw edge of channel extension, secure Size ‘A’ ‘B’ ‘C’ ‘D’ harness to channel using nylon wire tie No. 3, see 4 Section Figure 24f. 5 Section Use remaining nylon cable ties to secure harness to chaseway channel at every set of holes, start at 6 Section wire tie No. 4 and working forward, removing slack 7 Section...
- Page 42 a. 4 thru 8 section boilers are shipped with the c. BSD with right hand hinge arrangement - internal harness length suitable for an 8 section harness exits right side of jacket front panel en boiler. To modify harness for a 7 section, cut route to control panel. nylon wire tie A; for a 6 section, cut A & B; for 5 d. BSD with right hand hinge arrangement - section, cut A, B & C; and for a 4 section, cut A, harness exits left side of jacket front panel en B, C & D. Refer to Table IX and Figure 25. route to control panel. b. 9 thru 13 section boilers are shipped with the Locate two (2) cable clamps and secure harness to proper harness length suitable for a 13 section vertical rails with two (2) #8 x ½ hex head sheet boiler. For boiler sizes 9 thru 12, modify harness metal screws as shown in Figure 24g, clamp must be per Table IX, also refer to Figure 25. facing inward to prevent interference with jacket. c. 14 thru 18 section boilers are shipped with the 7. Adjust length of internal wiring harness to match proper harness length suitable for an 18 section boiler size, see Table IX and Figure 25 for details. boiler. For boiler sizes 14 thru 17, modify harness per Table IX, also refer to Figure 25. Figure 5: Internal Wiring Harness - Length Adjustment for Penetration Through Side of Jacket Front Panel...
- Page 43 step 3. Secure top corner panel #1 to next set of frame Locate Jacket Top Corner Panels packed in carton marked ‘JC-2’. Install Jacket Top Corner Panels per rails with two (2) #8 x ½” 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 align holes. illustration in Figure 26. step 1. On 4 thru 6 Section Boilers, assemble top NOTE: Like the lower tie bars installed corner panel #1 to 6¾” top corner panel #2 using previously, these top corner panels two (2) #8 x ½” lg. hex head sheet metal screws, maintain the proper distance between frame rails for assembly of remaining before installing on frame rails as noted in Step 2. jacket panels. step 2. Starting on the left side, at the front, secure step 4. On 7 thru 11 Section Boilers, locate top corner top corner panel #1 to front horizontal and vertical frame rails with two (2) #8 x ½” lg. hex head sheet panel #2 per Table X and secure to panel #1 using two (2) #8 x ½” lg. hex head SMS. Align mounting metal screws (SMS). holes in panel #2 with holes in frame rails and secure with two (2) #8 x ½” lg. hex head SMS. Table X: Jacket Top Corner / Intermediate Panel Arrangement Order of Assembly (* See Panel Designation Below) Side of Boiler Size...
- Page 44 step 5. On 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 ½” lg. Note: Right side of boiler uses same panels as left hex head SMS per joint. Align mounting holes in side with a reverse pattern starting at the rear panel(s) #3 with holes in frame rails and secure with and working forward. two (2) #8 x ½” lg. hex head SMS per rail. Locate Front Panel Shipped in Jacket Carton marked Locate top corner panel #2 per Table X and secure ‘JC-1’ - Position jacket front panel against front of to last top intermediate panel #3 installed, using two boiler assembly and feed internal harness wires through (2) #8 x ½” lg. hex head SMS. Secure panel #2 to holes in side of panel as shown in Figure 25. rear frame rails using two (2) #8 x ½” lg. hex head SMS. Figure 6: Install Top Corner / Intermediate Panels Figure 7: Install Jacket Front Panel...
- Page 45 Install front panel by tilting on a slight angle to engage Locate Jacket Split Rear Panel shipped in JC-1 Jacket top flange behind bottom flange on jacket top corner Carton. panels installed previously, see Figure 27, Detail A. Note: Before installing rear panel, drain valve and Rotate bottom of front panel until locking tabs rest indirect water heater return piping (furnished by against vertical frame rails. On one side only, flex side others) should be installed now due to of panel until hooks clear face of vertical rail. Align top accessibility. and bottom hooks with slotted holes nearest front edge. Rear panel is shipped loose in two (2) halves, see Engage both hooks and allow panel to drop down to Figure 28. As viewed from rear of boiler, install left lock in place. Repeat for opposite side. 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...
- Page 46 Table XI: Jacket Top Panel Arrangement Order of Assembly Boiler Size Front Block Assembly Rear 4 Section 22-1/4” Front Top Panel 11-3/8” Rear Top Panel 5 Section 29” Front Top Panel 11-3/8” Rear Top Panel 6 Section 35¾” Front Top Panel 11-3/8”...
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Page 47: Install Burner Swing Door (Bsd)
Figure 0b: Install Jacket Top Panels - Viewed From Rear Figure 0c: Install Jacket Rear Top Panel - Viewed From Rear 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 between outer top corner panes. Slide forward to engage locking tabs into slotted openings on previously installed panel, see Figure 30b. Secure rear flange with two (2) #8 x ½” lg SMS. Repeat 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... - Page 48 Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair 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°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
- Page 49 Lift door high enough to move hinge pockets through 2. On 4 thru 18 Section Boilers - Install four (4) second pass baffles into second pass flueways until handle opening in jacket front panel. Engage hinge loop is flush with face of casting as shown in Figure 33, attached to door over hinge pin attached to block assembly. Lower door to rest weight on hinge pin Detail A. brackets. Locate Flueway Baffle Carton(s) marked ‘2FB’ and ‘3FB’ and remove contents. Check Equipment Check List for proper baffle length and usage per boiler size. 1. On 4 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,...
- Page 50 excessive torque. Never tighten hardware on either side Close Burner Swing Door and secure using (4) 5/8” flat washers, (4) 9/16” lock washers and (4) 9/16 - 12 100% without using the alternating tightening method. x 2” lg. cap screws as shown in Figure 34. There are Failure to follow the prescribed procedure could cause (4) points of internal contact around perimeter of BSD thread damage, a crack in the casting or a leak in the and Front Section. These stop the door travel when door seal. tightening hardware to prevent excess compression Mount Burner Adapter Plate to Burner Swing Door, of rope gasket. Therefore, continued tightening of refer to Figures 35 and 36. hardware will only bend the hinge pockets. Use a hand Also, refer to Burner Installation Manual for mounting wrench to tighten the hardware. Use an alternating instructions specific to each burner (provided with tightening method from right side to left side cap burner). screws to secure door until sealed without applying Figure : Secure Burner Swing Door for Tight Perimeter Seal Figure 5: Install Burner Adapter Plate and Burner to Burner Swing Door...
- Page 51 11-11/16 MPC12 thru MPC18 602263081 8-1/8 1. In most cases the burner adapter plate carton for the CAUTION specified burner will be provided by Burnham. Failure to properly fill all gaps between the 2. If adapter is provided by Burnham, open carton and remove contents. Apply four (4) small dabs insulation and burner blast tube may result in damage to the burner. of silastic on rear surface of adapter plate to temporarily hold gasket in place. Hold adapter plate...
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Page 52: Probe Lwco
Figure 7: Install Jacket Front Panel Harness Cover Plates and Logo Plate 9. Connect other end of flexible conduit to burner 1. Harness is split into two (2) 7 wire bundles that exit side of front panel as shown in Figure 25. control panel or junction box. Connect control/ safety circuit wires to appropriate terminals per 2. Each seven (7) wire harness bundle must be encased in flexible conduit from cover plate to burner control wiring diagram provided with burner. panel or junction box. Install Logo Plate on Jacket Front Panel if Optional Jacket Split Burner Swing Door Cover Panels are not to 3. Locate front panel cover plates in JC-1 carton. - Page 53 4. Apply thread sealant to 3/4” immersion well Note: Supply manifold must be installed with 1½” and install in tapping ‘D’ as shown in Figure 38. couplings aligned with front and rear axis of boiler. Wrench well until water tight. 2. Apply thread sealant and install temperature/ 5. Locate L4006A Operating Control and remove pressure gauge into tapping ‘G’, see Figures 38 and knockout on casing closest to mounting hole. 39. Wrench until water tight. Tighten gauge using Connect end of harness with forked terminals to hex on stem, do not tighten or apply pressure to case. casing knockout. Connect wires to terminal on limit control, wires are interchangeable. Refer to Figure 3. Apply thread sealant and install relief valve and pipe fittings in Tapping ‘B’, see Figure 38. Fittings 6. Connect opposite end of L4006A Operating Control should be arranged as shown in Figure 39. By code, relief valve must be installed vertically. Based on Harness to right side junction box cover ‘A’, hole location #1 as shown in Figure 40. vent pipe arrangement and access, relief valve can be installed with discharge facing a left or right. 7. Locate mating connectors labeled “operating control” inside right junction box. Join mating connectors which are polarized and lock together. Lightly tug on...
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Page 54: High Limit Control W/ Manual Reset
Install 7/8” knockout plugs (provided) to all Installing Optional Controls (if applicable): unused holes, refer to Figure 40. 1. Install M&M 750P-MT-120 Probe Low Water Cut 2. Install High Limit Control w/Manual Reset Off (LWCO) (L4006E) a. Apply thread sealant to ¾” probe and install in a. Apply thread sealant to 3/4” immersion well Tapping ‘E’, see Figure 38. Wrench hex until and install in Tapping ‘F’ as shown in Figure 38. water tight. Wrench well until water tight. b. Remove 2 knockout from bottom of M&M b. Locate L4006E High Limit Control and 750P LWCO control case. Connect end remove knockout on casing closest to mounting of harness with forked terminals to casing hole. Connect end of harness with forked knockout, see Figure 41. Connect wires to terminals to casing knockout. Connect orange terminal block as follows: wires to terminals on limit control, wires are Terminal 1 - Black Wire w/ Red Tracer interchangeable. Refer to Figure 42. Terminal 2 - Pink Wire Terminal 3 - Red Wire w/ Black Tracer Terminal 4 - Brown Wire Terminal 5 - Violet Wire c. Mount LWCO Control on probe and tighten screws. d. Connect ring terminal on black probe wire from circuit board to terminal on probe and tighten wing nut. -
Page 55: Low / High / Low Control Or Modulating Control
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 ‘H’ 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. Figure : Install Low Fire Hold Control c. Connect opposite end of L4006B Low Fire Hold Control harness to right side junction box cover ‘A’, 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 ‘B’ to jacket rear top panel with two (2) #8 x 1/2” lg. hex head SMS per... -
Page 56: Install Flue Outlet Damper Assembly
v. Connect opposite end of T991A Modulating 2. Assemble two cap screw/washer combinations, then, insert cap screws/washers through a flue outlet Control harness to right side junction box cover ‘A’, hole location #4 as shown in damper assembly-mounting ring at 3 o’clock and 9 o’clock positions. Place the flue outlet damper Figure 40. vi. Locate mating connector labeled “LO-HI- gasket onto cap screws and position damper with gasket onto boiler rear flue collector, aligning screws LO/MOD” inside right junction box, see with flue collector threaded holes. - Page 57 4. Install right side BSD cover panel using the same Install Optional Split Jacket Panels for Burner Swing procedure used on left cover panel. Before locking Door (BSD) Cover (if applicable). panel in place, make sure right cover panel overlaps 1. Open carton and remove contents. offset flange of left cover panel. 2. Locate hanger bracket for BSD cover, secure to 5. Secure panels together at seam using six (6) #8 x jacket front panel with three (3) #8 x 1/2” hex head 1/2” lg. hex head SMS, one (1) screw on top and SMS as shown in Figure 47. five (5) screws on the face as shown in Figure 47. 3. Install left side BSD cover panel with offset bend as 6. Locate Logo Plate shipped in Instruction Envelope. shown in Figure 47. Engage hooks on outer edge of Peel paper off adhesive strips and install by inserting panel through slotted openings on jacket front panel positioning tabs on rear of Logo Plate into slotted installed on boiler. At the same time, engage top openings in upper left corner of left cover panel as flange of left cover panel behind hanger bracket, see...
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Page 58: Section Iv - Installation Instructions
SECTION IV - INSTALLATION INSTRUCTIONS PAcKAGED BOiLER WARNING 1. The packaged boiler comes on its own shipping 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 1½ TIMES THE DO NOT improperly pipe boiler. WORKING PRESSURE OF THE BOILER (see Section II, Paragraph C). The shipping skid can be used as a housekeeping pad unless local codes say... - Page 59 Boiler Operating Requirements: • Minimum Return Water Temperature = 80°f • Maximum Delta T = 80°f • Minimum supply Water Temperature = 130°f Supply Return NOTES: 20°F Rise 40°F Rise 1. All piping is schedule 40. Boiler Water Side Flow Water Side Flow Model 2. Pipe sizes listed are based on a 20°F Nom.
- Page 61 Boiler Operating Requirements: • Minimum Return Water Temperature = 80°f • Maximum Delta T = 80°f • Minimum supply Water Temperature = 130°f Supply Return NOTES: 20°F Rise 40°F Rise Boiler 1. All piping is schedule 40. Water Side Flow Water Side Flow Model Nom.
- Page 63 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°F must be maintained to avoid sustained condensing within the combustion chamber. b. Primary/Secondary Piping - If the conditions Figure 5: Typical Burnham Boiler - above cannot be met, then parallel piping Primary - Secondary Loop System systems must be converted to an arrangement c. Alternate Piping Arrangements - Piping that will provide the proper water flow through arrangements other than Parallel and Primary/ the boiler at the proper temperatures. Primary/ Secondary, such as System Bypass, are...
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Page 64: Boiler Piping - Domestic Hot Water
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. -
Page 65: Section V - Operating Instructions
SECTION V - OPERATING INSTRUCTIONS i. Close hose bib, continue filling the system until WARNING the pressure gauge registers normal system design operating pressure. Close fill valve. If you do not follow these instructions exactly, (Note - If make-up water line is equipped a fire or explosion may result causing property with pressure reducing valve, system will damage or personal injury. -
Page 66: Test Controls
TEsT cONTROLs WARNING WARNING Chemicals used in treating boiler water are toxic and/or harmful. Always use protective Before installation of the boiler is considered clothing and equipment when working with/ complete, the operation of the boiler controls near chemicals. Contact local authorities should be checked, particularly the low water to determine if treated boiler water can be cutoff and the high limit control. -
Page 67: Frequent Water Addition
5. Boiler is now ready to be put into service. Burnham’s standard warranty does not cover problems caused by oxygen contamination of fREQUENT WATER ADDiTiON boiler water or scale (lime) build-up caused by frequent addition of water. -
Page 68: Section Vi - Service Instructions
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. -
Page 69: Maintenance Of Low Water Cutoff Devices
f. Use a wire or fiber bristle brush of appropriate length and diameter to allow sufficient cleaning CAUTION of all flue passages. Using long strokes, push the Do not start the burner unless BSD, smokepipe, brush the whole way through the boiler and then flue clean-out covers and burner are all secured pull it out. Repeat this process until all surfaces in place. -
Page 70: General Maintenance Considerations
Complete replacement mechanisms, including WARNING necessary gaskets and installation instructions, are available from the manufacturer. Exercise caution when handling phosphoric acid chEcK BURNER AND cONTROLs at least once and follow the instructions on container label. Always use protective clothing and equipment a year. See Section V, Paragraph E under Operating when working with/near chemicals. Instructions for control checks. See Burner Manual and Table XII for recommended burner tests and i. Wire brushing of the probe is not recommended adjustments. as the soft platinum guard ring sandwiched LUBRicATE BOiLER cOMPONENTs according between the ceramic insulators may be damaged. - Page 71 Table XII: Recommended Periodic Testing Check List Frequency Item Accomplished by Remarks Gauges and Indicators Daily Operator Make visual inspection and record readings in log Instrument and Equipment Daily Operator Make visual check against recommended specifications Settings Firing Rate Control Weekly Operator Verify factory settings...
- Page 72 Table XII: Recommended Periodic Testing Check List (continued) Frequency Item Accomplished by Remarks High Limit Safety Control Annually Service Technician Refer to instructions Operating Control Annually Service Technician Refer to instructions Low Draft, Fan, Air Monthly Operator Refer to burner instructions Pressure, and Damper Position Interlocks High and Low Gas...
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Page 73: Section Vii - Burner Specifications
SECTION VII - BURNER SPECIFICATIONS NOTICE MPC boiler ratings and capacities are 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 XIIIa: Beckett #2 Oil Burner Specifications PUMP NOZZLE... - Page 74 Table XIVa: Power Flame #2 Oil Burner Specifications BURNER BURNER APPROX. HIGH FIRE HIGH FIRE DIFFUSER NOZZLE DATA BOILER MIN. MAX. BURNER DAMPER SETTING - PUMP NOZZLE OPENING GPH X ANGLE MODEL INPUT INPUT MODEL TOP / BOTTOM DAMPER PRESSURE MAKE (IN.) - TYPE...
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Page 76: Section Viii - Repair Parts
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. - Page 104 Appendix A - figures Figure Number Page Number Description Equipment Check List Carton Identification Figure 1a Section I - General Information Figure 1b Dimensional Information Figure 2 Boiler Foundation Figure 3a MPC With Rear Outlet Vent Figure 3b Vents - Faults and Suggestions Section II - Cast Iron Block Assembly Instructions (Knockdown Boilers) Lifting Instructions - Limited to 4 thru 12 Section Block Assembly Figure 4a...
- Page 105 Figure 50b Alternate MPC Minimum Piping - Multiple Boiler Application Figure 51 Parallel Piping Conversion Figure 52 Typical Burnham Boiler - Primary-Secondary Loop System Figure 53 Recommended Piping for Combination Heating & Cooling (Refrigeration) Systems Figure 54 Discharge Piping for Pressure Relief Valve...
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Page 106: Cast Iron Section Assembly
Appendix A - figures (continued) Figure Number Page Number Description Section VIII - Repair Parts Figure 55 MPC Cast Iron Section Assembly Description Cast Iron Section Assembly Figure 56 MPC Common Bare Boiler Components Description Common Bare Boiler Components Figure 56 MPC Common Bare Boiler Components (continued) Description Common Bare Boiler Components... - Page 107 Appendix B - Tables Table Number Page Number Description Section I - General Information Table I Dimensional Information Table II Ratings/Data Table III Recommended Rear Service Clearance Table IV Minimum Installation Clearances to Combustible Materials Table V Boiler Foundation Section II - Cast Iron Block Assembly Instructions (Knockdown Boiler) Table VI Proper Arrangement of Threaded Rods and Coupling Nuts Section III - Boiler Assembly Instructions (Knockdown Boiler)
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Page 108: Warranty
If any part of a commercial grade boiler or i. Any damage resulting from combustion air contaminated with particulate any part or accessory provided by Burnham Commercial is found to be defective in which cause clogging of the burner or combustion chamber including but material or workmanship during this one year period, Burnham Commercial will, at its not limited to sheetrock or plasterboard particles, dirt, and dust particulate.