Aerco MFC 3000 User Manual
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Aerco MFC 3000 User Manual

Multi-fuel condensing boilers
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MFC Series Boilers User Manual
USER MANUAL
Installation, Operation and Maintenance of:
MFC Series
Applies to MFC Series Models:
• MFC 3000
• MFC 4000
• MFC 5000
• MFC 6000
• MFC 8000
• MFC 10000
NOTE: Refer to the AERCO MFC Series Installation Manual, GF-146-IN, for preliminary
assembly and installation instructions and information.
Latest Update: 12/29/2015
OMM-0104_94
GF-146
Multi-Fuel Condensing Boilers
MFC 10000
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Page 1 of 170
12/29/2015

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  • Page 1 • MFC 6000 • MFC 8000 • MFC 10000 NOTE: Refer to the AERCO MFC Series Installation Manual, GF-146-IN, for preliminary assembly and installation instructions and information. Latest Update: 12/29/2015 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 2: Table Of Contents

    6.3 Flow Rate adjustment ........................35 6.4 Electrode Positioning ......................... 36 6.5 Burner Setup............................37 6.6 Hydraulic Connections ........................38 6.7 Pump ..............................39 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 2 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...
  • Page 3 6.10 Pump Adjustment ..........................43 6.11 Air Damper Adjustment ........................43 6.12 Ignition Pilot Adjustment ......................... 43 6.13 Adjustments before First Firing (Gas Operation) ................44 6.14 Startup for MFC 3000 Dual Fuel Burner ..................46 6.14.1 Gas/Air Delivery Adjustment ....................47 6.14.2 Adjusting Oil/Air Delivery ......................
  • Page 4 10.16.1 Combustion Air Adjustment ....................118 10.16.2 Air Adjustment for Maximum Output .................. 118 10.16.3 Gas/Air Delivery Adjustment ....................118 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 5 SECTION 13: MFC SERIES MAINTENANCE ............... 139 13.1 Preparation for Inspection and Maintenance ................139 13.2 Standard Maintenance ........................140 13.3 Burner Maintenance ........................141 13.4 RS-120 / RS-160 Burner Maintenance (MFC 3000-6000) .............. 141 13.4.1 Combustion ..........................141 13.4.2 Gas Leaks ..........................
  • Page 6 13.9 MFC 8000-10000 Sequence of Operation Diagram ..............147 APPENDIX B – ELECTRICAL DIAGRAMS ................150 MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8 ..............150 MFC 8000/10000 - ElectRICAL Diagrams 1-9 ..................159 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 7: Foreword

    FORWARD Foreword The AERCO MFC Series boilers are modulating and condensing units. The MFC Series represents a true industry advancement that meets the needs of today's energy and environmental concerns. Designed for application in any closed loop hydronic system, the MFC Series modulating capability relates energy input directly to fluctuating system loads.

  • Page 8: Section 1: Safety Precautions

    In addition to all the requirements included in this AERCO Instruction Manual, the installation of units MUST conform with local building codes, or, in the absence of local codes, ANSI Z223.1 (National Fuel Gas Code Publication No. NFPA-54) for gas-fired boilers and ANSI/NFPASB for LP gas-fired boilers, as well as NFPA 31 “Standard...

  • Page 9: Emergency Shutdown

    3. Inspect exhaust vent and air inlet duct work (if applicable). 4. Perform initial startup per Chapter 5. 5. Perform scheduled maintenance procedures per Chapters 6 of this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 9 of 170 Ph.: 800-526-0288...

  • Page 10: Massachusetts Installations

    • Prior to unit operation, the complete gas train and all connections must be leak tested using a non-corrosive soap. • AERCO provides an optional external CO Detector, part number 58092. It can be installed and conFigured to simply sound an alarm or to shut down the boiler(s) if CO concentrations rise above a configurable threshold.
  • Page 11 ____________________________________________________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 11 of 170 Ph.: 800-526-0288...

  • Page 12: Section 2: Introduction

    The warranty shall be valid only upon compliance with the instruction given in this manual. The AERCO MFC Series boilers have been built and tested in observance of ASME requirements and UL (In Process), when ordered with a factory supplied burner.

  • Page 13: General Technical Specifications

    MFC Series Boilers User Manual CHAPTER 2: INTRODUCTION 2.3 General Technical Specifications MFC Series General Technical Specifications MFC 3000 MFC 4000 MFC 5000 MFC 6000 MFC 8000 MFC 10000 Boiler Category ASME Sect.IV Max. Allowed Working Pressure 80 PSIG Max. Working Temperature 240°F...
  • Page 14 10000 70.9” 236.0” 102.3” 76.8” 183.2” 8.5” 87.1” 7.8” 22.8” 40.9” 86.8” 52.7” 3.0” 1.1” 18.0” 7.2” 70.9” 7.9” 35.4” AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...

  • Page 15: Section 3: Installation

    See Table A Tridicator 123675-2 Low Water Cut Off 121700 Condensate Trap 24441 Aquastat 64115 Manual Reset Aquastat 64116 Thermowell 99235 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 15 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 16 MFC Series Boilers User Manual CHAPTER 3 - INSTALLATION Table A - MFC Series Accessories Refer to the MFC Boiler Field Assembly (TID-0164) for more information. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 16 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 17 NUTS for CONN. PIPE LOCK WASHERS for CONN. PIPE TUBE CLEANING BRUSH DOOR OPENING TOOL Figure 2-1: MFC Factory Installed Parts AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 17 of 170 Ph.: 800-526-0288 GF-146...

  • Page 18: Site Preparation

    MFC boilers must have access to a Natural Gas line with the following minimum pressures with the unit at FULL FIRE: • MFC 3000 = 14” W.C. • Other MFC Models = 1 psi. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...

  • Page 19: Installation Clearances

    The MFC series boiler dimensions and minimum acceptable clearances are shown in Figures 4- 1 and 4-2. The minimum clearance dimensions, required by AERCO, are listed below. However, if Local Building Codes require additional clearances, these codes shall supersede AERCO’s requirements.

  • Page 20: Installation - Site

    3.5 Boiler Room Current regulations must always be observed. Premises in which boilers will be installed should be sufficiently ventilated and permit access for maintenance operations. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 21: Flue

    Operating Aquastat with thermal well • Manual Reset Aquastat with thermal well • Low-Water Cutoff Device • Tridicator • Condensate drain • Boiler drain AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 21 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...

  • Page 22: Electrical Connections

    National Electrical Code (NEC), ANSI/NFPA 70 and/or the Canadian Electrical Code (CEC) Part I, CSA C22.1 Electrical Code. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 23: Burner Door Opening Orientation

    The boiler door should be kept closed at all times while switching hardware and the instruction steps followed in the exact order as written. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 23 of 170 Ph.: 800-526-0288...
  • Page 24 4. Use a wrench to loosen and remove the lower right nut and remove it (Figure 3-7). STEP 4: Figure 3-7: Removing lower Right Nut with Wrench AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 25 If necessary, adjust as described in the next section. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 25 of 170 Ph.: 800-526-0288...

  • Page 26: Adjusting The Boiler Door - Vertical And Horizontal

    Retighten after preventing adjustment. installation. Figure 3-11: Example Problem for Adjusting Vertical Adjustment Nut on Hinge AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 27 Figure 3-12: Adjusting Horizontal Adjustment Nut on Hinge For any problems related to the reversal and adjustment of the door, we recommend contacting AERCO technical support team at 1-800-526-0288. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 27 of 170 Ph.: 800-526-0288...

  • Page 28: Section 4: Startup

    For more information concerning water quality and requirements, see the MFC Boiler Application Guide, GF-148-B. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 28 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 29: Filling The System

    Once the air has been entirely released, reset the pressure to the pre-established value and close the manual and/or automatic filling valve. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 29 of 170 Ph.: 800-526-0288...

  • Page 30: Section 5: Burner Installation

    Refer to section 11.1 of OMM-0108, MFC Series Boiler Installation Manual, GF-146-IN for burner installation instructions. Note that instructions are only applicable to Riello burner models RLS120, 160, 300 and RS 120, 160, 300 acquired through AERCO. For burners not acquired through AERCO, consult the respective burner manufacturer for proper installation instructions.

  • Page 31: Section 6: Mfc 3000 Dual Fuel Burner

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 31 of 170 Ph.: 800-526-0288...

  • Page 32: Mfc 3000 Dual Fuel Burner Features

    CHAPTER 6 – MFC 3000 DUAL FUEL BURNER 6.1 MFC 3000 Dual Fuel Burner Features Figure 6-1: MFC 3000 Dual Fuel Parts and Features AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 32 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 33 MFC Series Boilers User Manual CHAPTER 6 – MFC 3000 DUAL FUEL BURNER Key to Figure 6-1: MFC 3000 Dual Fuel Burner Parts and Features 1. Combustion head 2. Ignition electrodes 3. Screw for combustion head adjustment 4. Sleeve 5. Fan motor 6.

  • Page 34: Burner Nozzle Setup

    4. Fit the wrench through the central hole in the flame stability disk and loosen screws (1) per Figure 6-4. 5. Remove disk (2) per Figure 6-4 and replace the nozzles using the wrench (3). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 34 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 35: Flow Rate Adjustment

    With smaller pressure differences, the pressure on the nozzle return can be unstable. Figure 6-5: Nozzle Pressure and Flow Rate Chart The nozzle return pressure value is indicated by the pressure gauge (1) in Figure 6-6. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 35 of 170 Ph.: 800-526-0288...

  • Page 36: Electrode Positioning

    6.4 Electrode Positioning WARNING! Ensure that the electrodes are positioned as shown in Figure 6-7. Figure 6-7: Electrode Positioning AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...

  • Page 37: Burner Setup

    When fitting the burner on the two slide bars, it is advisable to gently draw out the high tension cables until they are slightly stretched. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 37 of 170 Ph.: 800-526-0288...

  • Page 38: Hydraulic Connections

    4. Now connect the other end of the hoses to the suction and return lines. Figure 6-10: Connecting the Hydraulics AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 38 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 39: Pump

    Whenever the length of the suction piping exceeds 66 - 98 ft., the supply line must be filled using a separate pump. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 39 of 170 Ph.: 800-526-0288...

  • Page 40: Gas Pressure

    Burner operating at maximum output. • Combustion head adjusted as indicated in diagram shown in Figure 6-15. Figure 6-13: Gas Manifold Pressure Measuring Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 41 1, natural gas. This value serves as a rough guide. The effective delivery must be measured at the gas meter. Maximum Output and WC Pressure Correlation Table AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 41 of 170 Ph.: 800-526-0288...

  • Page 42: Combustion Head Adjustment

    The chart shown in Figure 6-15 indicates that for this delivery, the combustion head must be adjusted using notch ( 3) shown in Figure 6-14. Figure 6-15: Maximum Burner Output AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 43: Pump Adjustment

    Position the pilot and electrode using the dimension shown in Figure 6-16. The pilot works correctly at pressures ranging from 3-4” W.C. Pilot Flange Electrode A = 1- 21/64” Figure 6-16: Ignition Pilot Adjustment AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 43 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...

  • Page 44: Adjustments Before First Firing (Gas Operation)

    Figure 6-18: Maximum Gas Pressure Switch 5. Adjust the air pressure switch shown in Figure 6-19 to the start of the scale. Figure 6-19: Air Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 45 Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 45 of 170 Ph.: 800-526-0288...

  • Page 46: Startup For Mfc 3000 Dual Fuel Burner

    NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 47: Gas/Air Delivery Adjustment

    4. Adjust the combustion parameter with the air servomotor and store the maximum combustion point. 5. To complete the procedure, synchronize the combustion with the two servomotors and store the different setting points. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 47 of 170 Ph.: 800-526-0288...

  • Page 48: Air Pressure Switch Adjustment

    3. If the burner locks out again, turn the knob counter-clockwise a little bit more. Figure 6-22: Air Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 49: Maximum Gas Pressure Switch Adjustment

    Adjust the minimum gas pressure switch shown in Figure 6-25 after having performed all the other burner adjustments with the pressure switch set at the start of the scale. Adjusting the Minimum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 49 of 170 Ph.: 800-526-0288...

  • Page 50: Low Oil Pressure Switch

    Px pressure feeds the burner, the pressure switch should be adjusted to Px + 43.5 PSI. Figure 6-26 shows the location of this adjustment. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 51: Burner Startup Sequence Of Operation

    The screw 6) closes the by-pass heading towards suction and the de-energized solenoid valves 8) - 9) - 2) close the passage to the nozzle. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 51 of 170 Ph.: 800-526-0288...

  • Page 52: Normal Operation Sequence Of Operation

    MAX. • If subsequently the temperature or pressure increases until the load control opens, the burner progressively decreases output down to MIN. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 53: Final Checks With Boiler In Operation

    Lockout Due To Firing Failure WARNING! Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 53 of 170 Ph.: 800-526-0288 GF-146...

  • Page 54: Section 7: Mfc 3000 Natural Gas Only Burner

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 55 MFC Series Boilers User Manual CHAPTER 7 – MFC 3000 GAS ONLY BURNER Figure 7-1: MFC 3000 Gas Only Burner Parts and Features AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 55 of 170 Ph.: 800-526-0288...
  • Page 56 1 relay k 5 relay k 3 relay k 2 relay Gas train flange Air pressure switch test point AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...

  • Page 57: Combustion Head Adjustment

    2. Tighten the 3 screws (1) fully down. 3. In the diagram in Figure 7-2, find the notch at which to adjust both air and central gas/air. Figure 7-2: MFC 3000 Gas Only Burner Parts and Features EXAMPLE: RS 120/E LN, burner output = 3750 MBtu/hr Consult the diagram in Figure 7-3 to see that for this output the adjustments are: •...
  • Page 58 The diagram in Figure 7-3 indicates an optimal calibration. Figure 7-3: MFC 3000 Gas Only Burner Parts and Features 4. If the pressure of gas allows it, by closing ring nut a reduction of the formation of NOx is obtained.

  • Page 59: Gas Supply Pressure

    Burner working at maximum output. • Ring nut (2) in Figure 7-2 adjusted as in the diagram of Figure 7-3. Figure 7-5: MFC 3000 Gas Only Gas Supply Pressure Test Points AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 59 of 170 Ph.: 800-526-0288...

  • Page 60: Figuring Burner Output

    2. In the diagram in Figure 7-6 find the pressure value closest to the result you want; read the corresponding output on the left. Figure 7-6: MFC 3000 Gas Only Burner Minimum Load Loss Chart Maximum Output Formula Example, Natural gas: •...

  • Page 61: Figuring Required Burner Output

    Pressure in combustion chamber = 1.18 “WC 6 + 1.18 = 7.15 “WC (Pressure required at pressure test point 1 in Figure 7-5) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 61 of 170 Ph.: 800-526-0288 GF-146...

  • Page 62: Adjustments Before First Firing (Gas)

    Figure 7-8: Maximum Gas Pressure Switch 5. Adjust the air pressure switch per Figure 7-9 to the start of the scale. Figure 7-9: Air Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 62 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 63 Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e. with gas delivery at the minimum. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 63 of 170 Ph.: 800-526-0288...

  • Page 64: Startup For Mfc 3000 Gas Only Burner

    NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 64 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 65: Gas/Air Delivery Adjustment

    3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point. 4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 65 of 170 Ph.: 800-526-0288...

  • Page 66: Air Pressure Switch Adjustment

    3. If the burner locks out again, turn the knob counter-clockwise in small increments until it does not. Figure 7-12: Air Pressure Switch Figure 7-13: Air Pressure Switch Connection AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 66 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 67: Maximum Gas Pressure Switch Adjustment

    3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C. Figure 7-15: Minimum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 67 of 170 Ph.: 800-526-0288...

  • Page 68: Final Checks With Boiler In Operation

    Cover the UV flame sensor. Firing Failure WARNING! Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 68 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...

  • Page 69: Section 8: Mfc 4000 / 6000 Dual Fuel Burner

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 69 of 170 Ph.: 800-526-0288...

  • Page 70: Mfc 4000-6000 Dual Fuel Burner Features

    CHAPTER 8 – MFC 4000/6000 DUAL FUEL BURNER 8.1 MFC 4000-6000 Dual Fuel Burner Features Figure 8-1: MFC 4000-6000 Dual Fuel Parts and Features AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 70 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 71 Pump motor contactor and t hermal relay with reset button Delivery oil solenoid valve Return oil solenoid valve DIN bar for fuse holder step-down transformer and OCI 412.10 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 71 of 170 Ph.: 800-526-0288 GF-146...

  • Page 72: Burner Nozzle Setup

    4. Fit the wrench through the central hole in the flame stability disk and loosen screws (1) in Figure 8-4. 5. Remove disk (2) in Figure 8-4 and replace the nozzles using the wrench (3). AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 72 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 73: Flow Rate Adjustment

    1), slightly decrease the pressure in the return line until they are completely eliminated. • Type A4 return flow nozzle (45°) • Delivery pressure 290 PSI AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 73 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 74 If pressure fluctuations are detected on the gauge (1) in Figure 8-4 at the maximum capacity of the nozzle (maximum pressure in the return line), slightly decrease the pressure in the return line until fluctuations are completely eliminated. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 74 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 75: Ignition Pilot Adjustment

    Turn the screw (6) in Figure 8-10 until the notch shown in diagram Figure 8-9 is level with the front surface of the flange (5) in Figure 8-10. Figure 8-9: Burner Maximum Output AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 75 of 170 Ph.: 800-526-0288...

  • Page 76: Pump Adjustment

    8.7 Air Damper Adjustment The first time the burner is fired leave the factory setting unchanged for both low and high fire operation. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 76 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 77: Electrode Positioning

    CHAPTER 8 – MFC 4000/6000 DUAL FUEL BURNER 8.8 Electrode Positioning WARNING! Ensure that the electrodes are positioned as shown in Figure 8-11. Figure 8-11: Electrode Positioning AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 77 of 170 Ph.: 800-526-0288 GF-146...

  • Page 78: Burner Setup

    When fitting the burner on the two slide bars, it is advisable to gently draw out the high tension cables until they are slightly stretched. Figure 8-13: Securing the Burner to the Boiler AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 78 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 79: Hydraulic Connections

    4. Now connect the other end of the hoses to the suction and return lines. Figure 8-14: Connecting the Hydraulics AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 79 of 170 Ph.: 800-526-0288...

  • Page 80: Pump

    Whenever the length of the suction piping exceeds 66 - 98 ft., the supply line must be filled using a separate pump. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 80 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 81: Gas Pressure

    Burner operating at maximum output. • Combustion head adjusted as indicated in diagram shown in Figure 8-9. Figure 8-17: Gas Manifold Pressure Measuring Locations AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 81 of 170 Ph.: 800-526-0288...

  • Page 82: Burner Firing

    Once the burner has fired, now proceed with calibration operations. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 82 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 83: Burner Calibration

    Figure 8-18: Minimum Gas Pressure Switch 4. Adjust the maximum gas pressure switch shown in Figure 8-19 to the end of the scale. Figure 8-19: Maximum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 83 of 170 Ph.: 800-526-0288...
  • Page 84 Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 84 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 85: Startup For Mfc 4000 - 6000 Dual Fuel Burner

    NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 85 of 170 Ph.: 800-526-0288...

  • Page 86: Gas/Air Delivery Adjustment

    4. Adjust the combustion parameter with the air servomotor and store the maximum combustion point. 5. To complete the procedure, synchronize the combustion with the two servomotors and store the different setting points. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 86 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 87: Air Pressure Switch Adjustment

    3. If the burner locks out again, turn the knob counter-clockwise a little bit more. Figure 8-23: Air Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 87 of 170 Ph.: 800-526-0288...

  • Page 88: Maximum Gas Pressure Switch Adjustment

    Adjust the minimum gas pressure switch shown in Figure 8-26 after having performed all the other burner adjustments with the pressure switch set at the start of the scale. Adjusting the Minimum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 88 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 89: Low Oil Pressure Switch

    Px pressure feeds the burner, the pressure switch should be adjusted to Px + 43.5 PSI. Figure 8-27 shows the location of this adjustment. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 89 of 170 Ph.: 800-526-0288...

  • Page 90: Burner Startup Sequence Of Operation

    The screw 6) closes the by-pass heading towards suction and the de-energized solenoid valves 8) - 9) - 2) close the passage to the nozzle. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 90 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 91: Normal Operation Sequence Of Operation

    MAX. • If subsequently the temperature or pressure increases until the load control opens, the burner progressively decreases output down to MIN. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 91 of 170 Ph.: 800-526-0288...

  • Page 92: Firing Failure

    Cover the UV flame sensor. Firing Failure WARNING! Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 92 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...

  • Page 93: Section 9: Mfc 4000-6000 Gas Only Burner

    Consult the diagram in Figure 9-2 to see that for this output the adjustments are: • Outside Air: R1 = notch 8.6. • Central Air: R2 = notch 0. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 93 of 170 Ph.: 800-526-0288 GF-146...
  • Page 94 Extension sliding bars slightly taut. Lifting rings Figure 9-3: Burner Reassembly Figure 9-4: Burner Reassembly AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 94 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...

  • Page 95: Gas Supply Pressure

    A maximum output of 4166 MBtu/hr corresponds to 2.95” W.C. pressure. This value serves as a rough guide; the effective delivery must be measured at the gas meter. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 95 of 170 Ph.: 800-526-0288...

  • Page 96: Adjustments Before First Firing

    Figure 9-7: Maximum Gas Pressure Switch 5. Adjust the air pressure switch shown in Figure 9-8 to the start of the scale. Figure 9-8: Air Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 96 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 97 Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e. with gas delivery at the minimum. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 97 of 170 Ph.: 800-526-0288...

  • Page 98: Startup For Mfc 4000-6000 Gas Only Burner

    NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam, supplied with the burner. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 98 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 99: Combustion Air Adjustment

    3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point. 4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 99 of 170 Ph.: 800-526-0288...

  • Page 100: Air/Fuel Control And Power Modulation System

    The first start-up and curve synchronization manual is supplied with the burner. The complete manual for checking and setting all parameters will be provided on application. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 100 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 101: Final Calibration Of The Pressure Switches

    3. If the burner locks out again, turn the knob counter-clockwise in small increments until it stops locking out. Figure 9-11: Air Pressure Switch and Connection Figure 9-12: Air Pressure Switch and Connection AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 101 of 170 Ph.: 800-526-0288...

  • Page 102: Maximum Gas Pressure Switch Adjustment

    3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C. Figure 9-14: Minimum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 102 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 103: Final Checks With Boiler In Operation

    Cover the UV flame sensor. Firing Failure WARNING! Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 103 of 170 Ph.: 800-526-0288 GF-146...

  • Page 104: Section 10: Mfc 8000 / 10000 Dual Fuel Burner

    AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 104 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 105: Mfc 8000-10000 Dual Fuel Burner Features

    CHAPTER 10 – MFC 8000/10000 DUAL FUEL BURNER 10.1 MFC 8000-10000 Dual Fuel Burner Features • Figure 10-1: MFC 8000-10000 Dual Fuel Parts and Features AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 105 of 170 Ph.: 800-526-0288...
  • Page 106 Oil shutoff VOG valve Nozzle delivery pressure gauge Nozzle return pressure gauge Oil modulator Strainer Check valve Air pressure test point “-” AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 106 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...

  • Page 107: Burner Nozzle Setup

    The nozzle for low fire operation is the one lying beneath the firing electrodes. • Make sure that the electrodes are positioned as shown in Figure 10-3, below. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 107 of 170 Ph.: 800-526-0288...

  • Page 108: Combustion Head Setting

    4) in Figure 10-5 supplied with the burner. Proceed as follows: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 108 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 109 2. Screw the spacers 4) onto spacer 1) and screw 5) respectively, Figure 10-5: Combustion Head Setting 3. Once done, refit the tie rod and nuts. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 109 of 170 Ph.: 800-526-0288...

  • Page 110: Hydraulic Connections

    3. Install the hoses where they cannot be stepped on or come into contact with hot surfaces of the boiler. 4. Now connect the other end of the hoses to the suction and return lines. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 110 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 111: Pressure Variator

    Figure 10-7: Hydraulic Gauges and Indicators KEY to Figure 10-7 1 = Nozzle pressure gauge 2 = Position indicator (0 - 90) of pressure variator AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 111 of 170 Ph.: 800-526-0288...

  • Page 112: Pump

    Whenever the length of the suction piping exceeds 66 - 98 ft., the supply line must be filled using a separate pump. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 112 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 113: Gas Train

    Table J: Minimum Pressure Losses MBtu/hr (GCV) 1 ∆p (“WC) 2 ∆p (“WC) 5112 0.63 5680 0.79 7574 1.38 9467 2.13 11361 13254 14390 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 113 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...

  • Page 114: Adjustments Before First Firing (Light Oil Operation)

    The setting of the combustion head depends exclusively on the maximum delivery of the burner. In case of high altitude site, consult the AERCO factory or Riello. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 115: Pump Pressure

    By setting switch (1) in Figure 10-11 to “REMOTE” you activate the remote fuel selection facility. In this position, if no remote selector is fitted, the display shows the priority fuel. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 115 of 170 Ph.: 800-526-0288...

  • Page 116: Adjustments Before First Firing (Gas Operation)

    Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 116 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 117: Burner Start-Up

    NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 117 of 170 Ph.: 800-526-0288...

  • Page 118: Combustion Air Adjustment

    3. Adjust the combustion parameters with the air servomotor and store the maximum combustion point. 4. Complete the procedure by synchronizing the combustion with the two servomotors and storing the different setting points. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 118 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 119: Adjusting Oil/Air Delivery

    The first start-up and curve synchronization manual is supplied with the burner. The complete manual for checking and setting all parameters will be provided on application. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 119 of 170 Ph.: 800-526-0288...

  • Page 120: Final Calibration Of The Pressure Switches

    To check this, insert a combustion analyzer into the chimney, slowly close the fan suction inlet (for example with cardboard) and check that the burner locks out, before the CO in the fumes exceeds 1%. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 120 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 121: Maximum Gas Pressure Switch Adjustment

    3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C. Figure 10-16: Minimum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 121 of 170 Ph.: 800-526-0288...

  • Page 122: Low Oil Pressure Switch

    Burner starts again automatically if the pressure goes above 261 PSI (18 bar) after burner start Figure 10-17: Maximum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 122 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 123: Burner Startup Sequence Of Operation

    17 Security relief valve 18 Pump 19 Piping 20 Piping Pressure gauge Vacuometer Figure 10-18: Burner Startup Sequence of Operation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 123 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...

  • Page 124: Normal Operation Sequence Of Operation

    Lockout Due To Firing Failure WARNING! Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 124 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...

  • Page 125: Section 11: Mfc 8000-10000 Gas Only Burner

    Air inlet to fan 24 Air pressure test point “-” Manifold 25 Ignition pilot attachment Thermal insulation screen for securing burner to boiler AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 125 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...

  • Page 126: Combustion Head Adjustment

    MFC 8000 MFC 10000 Max burner output Figure 11-3: Maximum Burner Output AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 126 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...
  • Page 127 2. Screw the spacers (4) onto spacer (1) and screw (5) respectively. 3. Once done, refit the tie rod and nuts. Figure 11-4: Adjusting the Combustion Head AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 127 of 170 Ph.: 800-526-0288...

  • Page 128: Rotation Of The Fan Motor

    3. Fit them to flange (1) tightening the nuts and screws. Figure 11-6: Gas Train Connection CAUTION! Once assembled, the gas train should be checked for leaks. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 128 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 129: Gas Pressure

    Gas butterfly + GCV MBtu/hr Head “WC Adaptor “WC 5112 0.63 5680 0.79 7574 1.38 9467 2.13 11361 13254 14390 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 129 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...

  • Page 130: Adjustments Before First Firing

    Figure 11-8: Maximum Gas Pressure Switch 5. Adjust the air pressure switch shown in Figure 11-9 to the start of the scale. Figure 11-9: Air Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 130 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 131 Before starting up the burner it is good practice to adjust the gas train so that ignition takes place in conditions of maximum safety, i.e., with gas delivery at the minimum. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 131 of 170 Ph.: 800-526-0288...

  • Page 132: Startup For Mfc 8000-10000 Gas Only Burner

    NOTE: For the start-up procedure and the parameters calibration, refer to the specific instruction manual of the LMV37 electronic cam supplied with the burner. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 132 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 133: Burner Firing

    Adjusting Gas/Air Delivery – Continued AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 133 of 170 Ph.: 800-526-0288...

  • Page 134: Air/Fuel Control And Power Modulation System

    The first start-up and curve synchronization manual is supplied with the burner. The complete manual for checking and setting all parameters will be provided on application. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 134 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 135: Final Calibration Of The Pressure Switches

    On RS 300-400-500/E burners the air pressure switch is fitted in a "differential" mode, that is, with two pipes connected to the specific pressure test points “+” and “-” 22) and 23) in Figure 11-1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 135 of 170 Ph.: 800-526-0288...

  • Page 136: Maximum Gas Pressure Switch Adjustment

    3. If the burner locks out again, turn the dial anti-clockwise again by 0.4” W.C. Figure 11-15: Minimum Gas Pressure Switch AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 136 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 137: Final Checks With Boiler In Operation

    Cover the UV flame sensor. Firing Failure WARNING! Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 137 of 170 Ph.: 800-526-0288 GF-146...

  • Page 138: Section 12: Flame Signal Measurement

    Cover the UV flame sensor. Firing Failure WARNING! Ensure that all lockout and safety procedures concerning all controls and valves are strictly observed. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 138 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...

  • Page 139: Section 13: Mfc Series Maintenance

    CAUTION: Before performing any maintenance on the boiler, ensure that the electrical connections and grounds have been made according to current standards. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 139 of 170 Ph.: 800-526-0288...

  • Page 140: Standard Maintenance

    FIGURE 13-1: Burner Tube and Turbulator Maintenance • Check the integrity of the electrical system on the boiler. • Perform a combustion testing and adjust as necessary. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 140 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015...

  • Page 141: Burner Maintenance

    Make sure that there are no gas leaks on the pipework between the gas meter and the burner. 13.4.3 Flame inspection Window Clean the flame inspection window (1) shown in Figure 13-2. FIGURE 13-2: Flame Inspection Window AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 141 of 170 Ph.: 800-526-0288 GF-146...

  • Page 142: Combustion Head

    Extract the UV scanner (2) Figure 13-4. • Clean the glass cover from any dust that may have accumulated. FIGURE 13-4: UV Scanner AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 142 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 143: Burner

    – To measure power, use a voltmeter with a 10 VDC scale, connected as illustrated in Figure 13- FIGURE 13-4: Detector Current Measurement Connections AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 143 of 170 Ph.: 800-526-0288...

  • Page 144: Fan

    13.7 Gas Operation (MFC 8000-10000 Only) 13.7.1 Gas Leaks Make sure that there are no gas leaks on the pipework between the gas meter and the burner. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 144 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 145: Gas Filter

    Combustion In case the combustion values found at the beginning of the inspection do not comply with local standard, codes, and/or guidelines, or otherwise exhibits improper combustion, contact AERCO technical support, for guidance in carrying out the necessary adjustments. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 146: Appendix A - Operational Sequence Diagrams

    MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS APPENDIX A – Operational Sequence Diagrams 13.8 MFC 3000-6000 Sequence of Operation Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 146 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 147: Mfc 8000-10000 Sequence Of Operation Diagram

    MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS 13.9 MFC 8000-10000 Sequence of Operation Diagram AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 147 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 148 MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 148 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 149 MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 149 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...

  • Page 150: Appendix B - Electrical Diagrams

    MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8 DIAGRAM LEGEND MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1 - 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 150 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 151 MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 1 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 151 of 170 Ph.: 800-526-0288...
  • Page 152 MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 2 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 152 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 153 MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 3 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 153 of 170 Ph.: 800-526-0288...
  • Page 154 MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 4 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 154 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 155 MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 5 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 155 of 170 Ph.: 800-526-0288...
  • Page 156 MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 6 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 156 of 170 OMM-0104_94 Ph.: 800-526-0288...
  • Page 157 MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 7 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 157 of 170 Ph.: 800-526-0288...
  • Page 158 MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 / 8000 - 8 of 8 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 158 of 170 OMM-0104_94 Ph.: 800-526-0288...

  • Page 159: Mfc 8000/10000 - Electrical Diagrams 1-9

    APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 8000/10000 - ElectRICAL Diagrams 1-9 DIAGRAM LEGEND MFC 8000 / 10000 Electrical Diagrams 1-9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 159 of 170 Ph.: 800-526-0288 GF-146...
  • Page 160 MFC Series Boilers User Manual APPENDIX B – ELECTRICAL DIAGRAMS MFC 10000 - 1 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 160 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 161 MFC Series Boilers User Manual APPENDIX A – OPERATIONAL SEQUENCE DIAGRAMS MFC 10000 - 2 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 161 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 162 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 3 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 162 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 163 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 4 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 163 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 164 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 – 5 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 164 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 165 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 6 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 165 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 166 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 7 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 166 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 167 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 8 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 167 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 168 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS MFC 10000 - 9 of 9 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 168 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...
  • Page 169 MFC Series Boilers User Manual APPENDIX A – ELECTRICAL DIAGRAMS NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_94 Page 169 of 170 Ph.: 800-526-0288 GF-146 12/29/2015...
  • Page 170 Description Changed By 12/29/2015 Rev-94: Added burner chapters and many changes. Curtis Harvey International Inc. © AERCO International, Inc., 2015 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 170 of 170 OMM-0104_94 Ph.: 800-526-0288 12/29/2015 GF-146...

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