Aerco MFC 3000 Installation And Startup Manual
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Aerco MFC 3000 Installation And Startup Manual

Mfc series multi-fuel condensing boilers
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Download this manual See also: User Manual, Installation Manual
MFC Series Boilers Installation, Startup Operation
Installation, Startup Guide & Operation
Multi-Fuel Condensing Boilers
Additional MFC Series Documentation:
• TAG-0077 GF-148-E MFC-Series Power- Application Guide
•
TAG-0078 GF-148-G MFC Series Gas Oil-2 Application Guide
•
TAG-0080 GF-146-V MFC Series Vent-Combust Air Application Guide
•
TAG-0081 GF-148-B MFC Series Application Guide
Latest Update: 2/28/2018
OMM-0104_0B
GF-148
USER MANUAL
MFC 10000 shown
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913
Ph.: 800-526-0288
Applies to MFC
Series Models:
• MFC 3000
• MFC 4000
• MFC 5000
• MFC 6000
•
•
PENDING
GF-148
MFC 8000
MFC 10000
Page 1 of 58
2/28/2018

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Summary of Contents for Aerco MFC 3000

  • Page 1 • TAG-0080 GF-146-V MFC Series Vent-Combust Air Application Guide • TAG-0081 GF-148-B MFC Series Application Guide Latest Update: 2/28/2018 PENDING AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 1 of 58 Ph.: 800-526-0288 GF-148 2/28/2018...

  • Page 2: Table Of Contents

    5.3 Burner Maintenance ............................ 36 APPENDIX A – ELECTRICAL DIAGRAMS ..................37 A1. MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8 ................38 A2. MFC 8000-10000 - Electrical Diagrams 1-9 ....................47 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...

  • Page 3: 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 4 MFC Series Boilers Installation, Startup Operation FORWARD (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 4 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...

  • Page 5: 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 6: 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 5 of this manual. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 6 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 7: Moving The Mfc Boiler

    MFC boilers and avoid equipment damage. LIFTING POINTS Figure 1-2: MFC Boiler Lifting Points AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 7 of 58 Ph.: 800-526-0288...

  • Page 8: Massachusetts Installations

    248 CMR 5.08(2)(a)1 through 4. (b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a)1 through AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 8 of 58 OMM-0104_0B Ph.: 800-526-0288...
  • Page 9 ____________________________________________________________________________ [End of Extracted Information From 248 CMR 5.08 (2)] AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 9 of 58 Ph.: 800-526-0288...
  • Page 10 MFC Series Boilers Installation, Startup Operation SECTION 1: SAFETY PRECAUTIONS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 10 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...

  • Page 11: 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 when ordered with a factory supplied burner.

  • Page 12: General Technical Specifications

    60 degree delta T across the heat exchanger. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 12 of 58 OMM-0104_0B Ph.: 800-526-0288...
  • Page 13 MFC3000-6000 : 2” NPT LOW TEMP CONDENSATE DRAIN RETURN DRAIN MFC8000-10000 : 3” NPT FLANGED Figure 2-1: MFC Series Dimensional Drawing AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 13 of 58 Ph.: 800-526-0288 GF-148 2/28/2018...
  • Page 14 MFC Series Boilers Installation, Startup Operation SECTION 2: INTRODUCTIONS (This page intentionally blank) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 14 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...

  • Page 15: Section 3: Installation

    The MFC series boiler dimensions and minimum acceptable clearances are shown in Figures 3- 1 and 3-2. 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 16 Figure 3-1: MFC Series – Single Unit Installation Clearances AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 16 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 17: Installation - Site

    3.3 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 OMM-0104_0B Page 17 of 58 Ph.: 800-526-0288...

  • Page 18: Flue

    See Section 3.13 for gas train installation instructions. Figure 3-3: MFC Series – Water Connections and Components Example AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 18 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018...

  • Page 19: 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 OMM-0104_0B Page 19 of 58 Ph.: 800-526-0288...

  • Page 20: Burner Door Opening Orientation

    USES WRENCH OPENING-SIDE HINGE-SIDE SAME HINGES ON BOTH SIDES WASHER & NUT Figure 3-4: Factory Installed Burner Door Hardware Configuration AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 20 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...

  • Page 21: Reversing The Opening Direction Of The Burner Door

    3. Use the door opening tool to loosen upper left nut & washer and remove. STEP 3: Figure 3-6: Removing Upper Left Nut and Washer with Door Opening Tool AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 21 of 58 Ph.: 800-526-0288...
  • Page 22 When cross-changing the barrel nuts, always make sure that the other two barrel nuts are fastened, so that they hold the door. WARNING! NEVER REMOVE ALL FOUR BARREL NUTS AT THE SAME TIME! AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 22 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 23: Adjusting The Boiler Door - Vertical And Horizontal

    If the boiler door is not seating over the boiler opening properly, or if there are problems inserting the barrel nuts over the hinge bolts, perform the following. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 23 of 58 Ph.: 800-526-0288...
  • Page 24 Figure 3-11: Example Problem for Adjusting Vertical Adjustment Nut on Hinge AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 24 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...
  • Page 25 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_0B Page 25 of 58 Ph.: 800-526-0288...

  • Page 26: Condensate Trap Installation

    (examples shown in Figure 3-14) for ease of maintenance of the 4th pass. Figure 3-14: Condensate Drain Diverting Valves for Duel Fuel Applications (Provided By Others) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 26 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 27: Control & Safety Devices

    SECONDARY PRESSURE RELIEF VALVE PORT (Optional) PIPE NIPPLE BUSHING Figure 3-15: Location of Safety Relief Valve & Other Safety & Control Devices AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 27 of 58 Ph.: 800-526-0288 GF-148...

  • Page 28: Burner/Blower

    MFC Series Boilers Installation, Startup Operation SECTION 4: STARTUP 3.12 Burner/Blower Refer to the Figure 3-16 for location of blower/burner gas and oil connections for AERCO supplied Riello burners. REVERSIBLE GAS INLET CONNECTIONS Figure 3-16: Blower/Burner Gas and Oil Connection Locations 3.12.1...

  • Page 29: Requirements

    Alternate material may be used as insulating material if necessary. BLOWER/BURNER BLAST TUBE THERMAL INSULATION (WHITE) Figure 3-17: Thermal Insulation AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 29 of 58 Ph.: 800-526-0288 GF-148...

  • Page 30: Gas Train Installation

    SECTION 4: STARTUP 3.13 Gas Train Installation The gas train for Riello burners acquired from AERCO is shipped loose and must be assembled and installed at the site, as shown below. Electrical connections for gas train components are shown in Appendix A.

  • Page 31: 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 OMM-0104_0B Page 31 of 58 Ph.: 800-526-0288...

  • Page 32: Filling The System

    ) level of 6% minimum for all firing rates with a smoke level less than • Maintain Carbon Di-Oxide level of 11% maximum for all firing rates with a smoke level less than 1. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 32 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 33: Section 5: 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_0B Page 33 of 58 Ph.: 800-526-0288...

  • Page 34: Standard Maintenance

    If a more thorough cleaning is necessary, the Stainless Steel 4th Pass has a total of eight (8) access ports to allow cleaning from the backside of the boiler. See next maintenance item for 4 Pass cleaning procedure. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 34 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 35: 4Th Pass Inspection And Cleaning

    5. Once cleaning is complete, close all access ports, and resume operation of the unit. • 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 OMM-0104_0B Page 35 of 58 Ph.: 800-526-0288 GF-148...

  • Page 36: Burner Maintenance

    Disconnect the electricity supply from the burner by means of the main switch of the system. • Close the fuel interception tap. AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 36 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 37: Appendix A - Electrical Diagrams

    Connect the safety and control devices supplied with the boiler to the burner control terminals shown below AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 37 of 58 Ph.: 800-526-0288...

  • Page 38: A1. Mfc 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8

    A1. MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1-8 DIAGRAM LEGEND MFC 3000 / 4000 / 5000 / 6000 Electrical Diagrams 1 - 8 (page 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913...
  • Page 39 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 1 of 8 (sheet 3) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 39 of 58 Ph.: 800-526-0288...
  • Page 40 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 2 of 8 (sheet 4) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 40 of 58 OMM-0104_0B Ph.: 800-526-0288...
  • Page 41 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 3 of 8 (sheet 5) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 41 of 58 Ph.: 800-526-0288...
  • Page 42 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 4 of 8 (sheet 6) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 42 of 58 OMM-0104_0B Ph.: 800-526-0288...
  • Page 43 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 5 of 8 (sheet 7) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 43 of 58 Ph.: 800-526-0288...
  • Page 44 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 6 of 8 (sheet 8) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 44 of 58 OMM-0104_0B Ph.: 800-526-0288...
  • Page 45 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 7 of 8 (sheet 9) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 45 of 58 Ph.: 800-526-0288...
  • Page 46 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 3000 / 4000 / 5000 / 6000 - 8 of 8 (sheet 10) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 46 of 58 OMM-0104_0B Ph.: 800-526-0288...

  • Page 47: A2. Mfc 8000-10000 - Electrical Diagrams 1-9

    APPENDIX A: ELECTRICAL DIAGRAMS A2. MFC 8000-10000 - Electrical Diagrams 1-9 DIAGRAM LEGEND MFC 8000 / 10000 Electrical Diagrams 1-9 (sheet 2) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 47 of 58 Ph.: 800-526-0288 GF-148...
  • Page 48 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 1 of 9 (sheet 3) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 48 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...
  • Page 49 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 2 of 9 (sheet 4) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 49 of 58 Ph.: 800-526-0288 GF-148 2/28/2018...
  • Page 50 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 3 of 9 (sheet 5) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 50 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...
  • Page 51 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 4 of 9 (sheet 6) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 51 of 58 Ph.: 800-526-0288 GF-148 2/28/2018...
  • Page 52 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 – 5 of 9 (sheet 7) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 52 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...
  • Page 53 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 6 of 9 (sheet 8) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 53 of 58 Ph.: 800-526-0288 GF-148 2/28/2018...
  • Page 54 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 7 of 9 (sheet 9) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 54 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...
  • Page 55 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 8 of 9 (sheet 10) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 55 of 58 Ph.: 800-526-0288 GF-148 2/28/2018...
  • Page 56 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS MFC 8000 / 10000 - 9 of 9 (sheet 10) AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 56 of 58 OMM-0104_0B Ph.: 800-526-0288 2/28/2018 GF-148...
  • Page 57 MFC Series Boilers Installation, Startup Operation APPENDIX A: ELECTRICAL DIAGRAMS NOTES: AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0104_0B Page 57 of 58 Ph.: 800-526-0288 GF-148 2/28/2018...
  • Page 58 Pass Maintenance instructions, format changed to new standard, revised diagrams in Appendix A1 and A2, and misc. changes. © AERCO International, Inc., 2018 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 58 of 58 OMM-0104_0B Ph.: 800-526-0288...

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