Burnham MPO, MPO84, MPO147, MPO189, MPO231 Installation & Service Instructions Manual

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As an ENERGY STAR Burnham Hydronics has determined that the MPO84, MPO147, MPO189 and MPO231 meet the ENERGY STAR guidelines for Energy effi ciency established by the United States Environmental Protection Agency (EPA).
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Partner,
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100103-01R3-10/05
Price - $3.00
IMPORTANT INFORMATION - READ CAREFULLY
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The following terms are used throughout this manual to bring attention to the presence of hazards
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of various risk levels, or to important information concerning product life.
REGNAD
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3
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STNETNOCFOELBAT
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5
6
Figure 1: MPO 84 Thru MPO 231 Water Boiler
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TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1)
48OPM"8/5-61"42"507.792.31034
HPGHBM
132OPM"8/5-43"63"748.7192.43177
981OPM"8/5-82"03"664.4192.72856
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TABLE 1B: RATING DATA
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741OPM50.17419212116 8X8510.78
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48OPM06.04847466 8X8510.78
132OPM56.11323027717 8X8510.78
981OPM53.19817615417 8X8510.78
7
SECTION I: PRE-INSTALLATION
A. INSPECT SHIPMENT carefully for any signs of
damage.
1. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated boiler to the carrier in good condition.
2. Any claims for damage or shortage in shipment must be fi led immediately against the carrier by the consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after receipt of goods.
B. LOCATE BOILER in front of fi nal position before
removing crate. See Figure 1.
1. LOCATE so that vent pipe connection to chimney will be short and direct.
2. BOILER IS SUITABLE FOR INSTALLATION ON COMBUSTIBLE FLOOR. Boiler cannot be installed on carpeting.
3. FOR BASEMENT INSTALLATION, provide a solid elevated base, such as concrete, if fl oor is not level, or if water may be encountered on fl oor around boiler.
4. PROVIDE RECOMMENDED SERVICE CLEARANCE, if applicable, as follows:
a. Clearance from Jacket Front Panel -
24" for servicing burner
24" for ueway cleaning (MPO84 & 147)
30" for ueway cleaning (MPO189)
36" for ueway cleaning (MPO231)
b. Clearance from Jacket Left Side Panel -
19" for burner swing door, if opened fully with burner mounted, otherwise 1" with burner removed
12" access clearance to service rear of boiler if right side clearance is less than 12"
• 1" minimum if right side clearance is 12" or larger to access and service rear of boiler.
c. Clearance from Jacket Right Side Panel -
3" minimum if left side clearance is 12" or larger to access and service rear of boiler.
d. Clearance from Jacket Rear Panel -
12" minimum for rear smokebox cleaning
(Note: This dimension will also be
controlled by horizontal to vertical to horizontal smokepipe arrangement - See Figures 2 and 16.)
5. For minimum clearances to combustible materials. See Figure 2.
ECITON
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Figure 2: Minimum Installation Clearances To Combustible Materials (Inches)
NOTES:
1. Listed clearances comply with American National Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.
2. MPO boilers can be installed in rooms with clearances from
8
combustible material as listed above. Listed clearances cannot
be reduced for alcove or closet installations.
3. For reduced clearances to combustible material, protection must be provided as described in the above ANSI/NFPA 31 standard.
C. PROVIDE COMBUSTION AND VENTILATION
AIR. Local and National Codes may apply and should
be referenced.
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1. Determine volume of space (boiler room). Rooms communicating directly with the space in which the appliances are installed, through openings not furnished with doors, are considered a part of the space.
Volume(ft3) = Length(ft) x Width(ft) x Height(ft)
2. Determine total input of all appliances in the space.
Add inputs of all appliances in the space and round
the result to the nearest 1000 BTU per hour.
3. Determine type of space. Divide Volume by total input of all appliances in space. If the result is greater than or equal to 50 ft3/1000 BTU per hour, then it is considered an uncon ned space. If the result is less than 50 ft3/1000 BTU per hour then the space is considered a con ned space.
4. For boiler located in an uncon ned space of a conventionally constructed building, the fresh air infi ltration through cracks around windows and doors normally provides adequate air for combustion and ventilation.
5. For boiler located in a confi ned space or an unconfi ned space in a building of unusually tight construction, provide outdoor air.
a. Outdoor air for combustion may be provided
with an optional Burnham MPO (V8) Inlet Air Accessory Kit, Part Number 611280031 (only
available and suitable for use on Beckett AFG with burner enclosure cover burner). See
Section V for installation details.
or b. Outdoor air may be provided with the use of two
permanent openings which communicate directly or by duct with the outdoors or spaces (crawl or attic) freely communicating with the outdoors. Locate one opening within 12 inches of top of space. Locate remaining opening within 12 inches of bottom of space. Minimum dimension of air opening is 3 inches. Size each opening per following:
i. Direct communication with outdoors.
Minimum free area of 1 square inch per 4,000 BTU per hour input of all equipment in space.
ii. Vertical ducts. Minimum free area of 1
square inch per 4,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.
iii. Horizontal ducts. Minimum free area of 1
square inch per 2,000 BTU per hour input of all equipment in space. Duct cross-sectional area shall be same as opening free area.
Alternate method for boiler located within
confi ned space. Use indoor air if two
permanent openings communicate directly with additional space(s) of suffi cient volume such that combined volume of all spaces meet criteria for unconfi ned space. Size each opening for minimum free area of 1 square inch per 1,000 BTU per hour input of all equipment in spaces, but not less than 100 square inches.
6. Louvers and Grilles of Ventilation Ducts a. All outside openings should be screened and
louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of rain and snow.
b. Free area requirements need to consider the
blocking effect of louvers, grilles, or screens protecting the openings. If the free area of the louver or grille is not known, assume wood louvers have 20-25 percent free area and metal louvers and grilles have 60-75 percent free area.
c. Louvers and grilles must be fi xed in the open
position, or interlocked with the equipment to open automatically during equipment operation.
9
SECTION II: PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS
A. REMOVE CRATE.
1. Remove all fasteners at crate skid.
2. Lift outside container and remove all other inside protective spacers and bracing. Remove burner and miscellaneous parts cartons.
B. REMOVE BOILER FROM SKID.
1. To reduce the risk of damage to boiler jacket, use the following procedure to remove from skid, see Figure 3:
Step 1. Boiler is secured to base with (4) 5/16" cap
screws, (2) in front and (2) in rear of shipping skid, see Figure 3. Remove all securing hardware.
Step 2. Place wooden block(s) 12" from rear of
skid as shown (one piece 4" x 4" x 16" lg. or two pieces of 2" x 4" x 16" lg.)
Step 3. Insert 1" Sch. 40 pipe handles through leg
hole in front and rear legs. Center end of pipe on wooden blocks as shown in Figure 3.
NOTE: Pipe handles should extend a minimum
of 48" beyond jacket front panel for best leverage.
Step 4. Using the pipe handles, lift boiler until
adjustable legs are elevated above the deck boards.
Step 5. Remove skid from underneath the boiler. Step 6. Lower pipe handles until front adjustable
legs touch fl oor. If necessary, place wooden
blocks under front legs before lowering to provide hand clearance.
Step 7. To lower rear of boiler, tilt unit slightly
forward by pushing on smokebox collar or lift pipes protruding through rear legs until wooden blocks can be removed (see Figure 3). Slowly allow the weight of the boiler to tilt backward until rear legs rest on fl oor.
Step 8. If wood block was placed under front legs,
lift pipe handles, remove wooden block and lower front legs to fl oor. Remove pipe handles.
NOITUAC
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.roolftsniagatekcaj
C. MOVE BOILER TO PERMANENT POSITION
by sliding or walking.
D. PROCEDURE TO OPEN, CLOSE AND
SECURE BURNER SWING DOOR
Throughout this manual you will be instructed to open
and close the burner swing door for various reasons. There is a proper and improper method to closing and securing the burner swing door opened for inspection, cleaning or fi eld service.
1. TO OPEN BURNER SWING DOOR (see Figures 4A and 4B).
Step 1. Loosen but do not remove left side latching
hardware (3/8" x 1-3/4" lg. tap bolt).
Figure 3: Packaged Boiler Removal from Skid
10
Figure 4A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured
Step 2. Loosen and remove right side latching
hardware (5/16" x 1-3/4" lg. tap bolt and washer).
Step 3. Remove left side latching hardware (5/16" x
1-3/4" lg. tap bolt and washer).
Step 4. Disconnect burner power cord from
receptacle located in lower right corner of jacket front panel.
Step 5. Door can be swung to the fully open
position, approximately 90° to 120°, with the burner mounted providing that there is 19" of clearance to the adjacent wall, see Figure 1.
NOTE: If reduced clearance prevents the door
from opening fully, one of the following can provide full access:
a. Burner can be removed to allow full rotation
of door.
b. Door with burner mounted can be lifted
off mounting bracket and set aside during servicing.
c. The door mounting hardware is reversible
from left side hinge (as shipped) to right side hinge.
To reverse hinge arrangement (see Figure
4A):
Lift door off mounting bracket and set aside.
Remove mounting bracket and hardware from left side.
Remove upper jacket front panel retaining screw (5/16" x 1/2" lg. Phillip Pan head machine screw) from right side of door and re-install in vacated upper mounting bracket tapping. Do not tighten.
Move lower jacket panel retaining screw from right side to left tapping. Do not tighten.
Rotate door mounting bracket 180°. Insert 5/16" cap screw through top hole in bracket and install in upper vacated jacket hole on right side of door.
Install second 5/16" cap through bracket hole into lower vacated tapping on right side.
Tighten both sets of hardware to secure jacket and mounting bracket.
Lift door and place integral cast hinge pins on door into slotted mounting bracket holes.
2. Perform routine inspection, service or cleaning as necessary.
3. To close Burner Swing Door (see Figures 4A and 4B):
Step 1. From the fully open position, rotate Burner
Swing Door to the closed position.
Step 2. If necessary, place your right hand under
the burner air tube to lift upward. Lift the door up unto the built-in cast ramp/door rest
11
Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)
12
(protruding from the bottom of the front section casting - see Figure 4A).
Step 3. Use one hand to help hold door in position
by lifting up on rear burner housing or applying pressure directly to the door while re-installing the securing hardware with your opposite hand.
Always install right side latching hardware (5/16" x 1-3/4" lg. tap bolt and fl at washer) rst, then install left side hinge hardware (5/16" x 1-3/4" lg. tap bolt and fl at washer) second.
Apply additional pressure while hand tightening the hardware as far as possible, then release the pressure.
E. INSPECT SWING DOOR INSULATION AND
ROPE GASKET.
1. Open burner swing door using procedure previously outlined in Paragraph D of this section.
2. Inspect fi berglass rope located on the swing door. The rope must be evenly distributed around the perimeter of the door groove and cannot bunch or overhang. There must not be a gap where the two ends of the rope meet. Repair or replace if the rope is damaged or if there is a gap between the ends.
3. Inspect burner swing door insulation for damage and proper type.
ECITON
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Step 4. Use a hand wrench to tighten door hardware
and always start with the right side cap screw rst. Use an alternating tightening method from right side tap bolt to left side tap bolt to tighten door equally until sealed without applying excessive torque. Never tighten left side fl ange bolt fi rst or tighten either piece of hardware 100% without using the alternating tightening method described above.
Failure to follow the prescribed procedure could
cause thread damage to casting or a leak in the door seal. If left side tap bolt is tightened before right side tap bolt, right side of door can not be drawn-in to provide an air tight seal, as shown in Figure 4C. Applying excessive torque will only cause thread damage.
a. By design, cast bars on front section between
the combustion chamber and between the left and right side 2nd and 3rd pass fl ueway should make an impression in door insulation to seal the chambers.
b. By design, door insulation on model MPO231
will have two (2) by-pass pockets cast into the insulation centered on the bar between the combustion chamber and 3rd pass fl ueways.
On models MPO84 thru MPO189 these pockets
should not be present. If insulation is damaged or not of proper type regarding pockets, it must be replaced.
4. Do not close and secure door at this time, proceed to Field Assembly Details, Paragraph F.
F. FIELD ASSEMBLY OF BOILER TRIM AND
CONTROLS
Open miscellaneous parts carton and remove contents.
Identify the components using the illustrations (Figures
Figure 4C: Top View - Burner Swing Door Fully Closed but Not Properly Secured or Sealed
13
5 thru 12) throughout the assembly sequence outlined below as it applies to your installation.
1. Install supply manifold and aquastat control, refer to Figure 5.
Step a. Remove two (2) #8 x 1/2" lg. sheet metal
screws securing jacket top rear panel to jacket rear panel. Slightly lift and pull jacket top rear panel away from jacket top panel to gain access to internal J-box wiring harness.
Step b. Locate the cast iron supply manifold shown
in Figure 5. Apply thread sealant to 1-1/2" NPT male threads. Thread male end into 1-1/2" NPT top tapping on rear section. Using hex head on top, tighten manifold until 1/2" NPT boss for control well is facing forward and joint is water tight.
Step c. Locate 1/2" NPT x 1-1/2" immersion well.
Apply thread sealant to 1/2" NPT male threads. Thread well into 1/2" NPT boss on front of supply manifold. Using hex head, tighten well until water tight.
Step d. Locate L7248C Aquastat Control/Harness
Assembly. Loosen mounting screw on bottom of case. Insert sensor into immersion well. Mount control on immersion well and tighten screw to secure control in horizontal position with harness on right side as shown in Figure 5.
Step e. Insert two (2) brown thermostat wires and
three (3) aquastat wires with Molex socket connector located on opposite end of aquastat harness through 7/8" dia. blank knockout in jacket top panel. Fish these wires to rear of internal junction box. Insert snap-in conduit connector in 7/8" blank knockout, squeeze tabs on side of connector, push into knockout and release tabs to lock connector in place.
Step f. Inside internal junction box, locate wires
with mating aquastat plug connector labeled "Aquastat" (refer to Figure 6 for details of harness located inside internal junction box). Align mating halves of socket connector from aquastat control with harness plug connector. Push connectors together until snap on connector is locked in place.
2. If required on this water boiler application, install low water cut-off (LWCO) Kit, optional equipment
- Burnham P/N 100106-01, refer to Figure 7. Also refer to instructions provided with LWCO Kit.
If not required, proceed to Paragraph 3.
Step a. Apply sealant to probe threads and install
in 3/4" NPT tapping on right side of manifold as shown. Tighten so that the mounting screws are horizontally aligned and joint is water tight.
Step b. Remove wing nut from the probe terminal.
Loosen screw and open cover on control box.
Figure 5: Supply Manifold and Aquastat Control Assembly Details
14
Figure 6: Internal Junction Box and Wiring Harness Details
Mount the control box on the probe by aligning the keyhole slots with the probe mounting screws. Replace the wing nut. Secure the control box by tightening wing nut and two (2) mounting screws.
Step c. Remove snap-in plug from 7/8" dia. center
knockout, adjacent to aquastat control harness.
Step d. Insert three (3) wires with Molex connector
located on opposite end of LWCO harness through 7/8" dia. knockout. Fish wires with Molex connector to rear of internal junction box. Insert snap-in conduit connector into 7/8" dia. knockout, squeeze tabs on side of connector, push into knockout and release tabs to lock connector in place.
Step e. Inside internal junction box, locate wires
with mating LWCO socket connector labeled "LWCO" (refer to Figure 6 for details of harness located inside internal junction box). Remove the factory installed socket plug jumper from LWCO harness socket connector and discard. Align mating halves of plug connector from LWCO control with harness socket connector. Push connectors together until snap on side of connector is locked in place.
3. If required on this water boiler application, install Auxiliary Dual Limit Control Kit, optional equipment - Burnham P/N 100107-01, refer to Figure 8. Also refer to instructions provided with Auxiliary Dual Limit Control Kit.
If not required, proceed to Paragraph 4.
Step a. Locate 1/2" NPT x 1-1/2 immersion well.
Apply thread sealant to 1/2" NPT male threads. Thread well into 1/2" NPT boss on left side of supply manifold. Using hex head, tighten well until water tight.
Step b. Locate L4080B Auxiliary Limit Control/
Harness Assembly. Loosen mounting screw on side of case. Insert sensing bulb into immersion well. Mount control on immersion well and tighten screw to secure control in vertical position with harness extending toward rear as shown in Figure 8.
Step c. Remove snap-in plug from 7/8" dia.
knockout closest to supply manifold. Remove locking ring from 90° conduit connector on end of control harness.
Step d. Insert two (2) wires with Molex connector
located on end of auxiliary limit control harness through 7/8" dia. knockout. Fish wires with Molex connector to rear of internal junction box. Insert 90° conduit connector into 7/8" dia. knockout, secure to top panel with locking ring.
Step e. Inside internal junction box, locate wires
with mating auxiliary limit socket connector labeled "Aux. Limit" (refer to Figure 6 for details of harness located inside internal junction box). Remove the factory installed socket plug jumper from harness socket connector and discard. Align mating halves of plug connector
15
Figure 7: Optional Equipment - Low Water Cut-Off (LWCO) Control Assembly Details
Figure 8: Optional Equipment - Auxiliary Limit Control Assembly Details
from auxiliary limit control with harness socket connector. Push connectors together until snap, on side of connector, is locked in place.
4. Install return manifold and relief valve, refer to Figure 9.
Step a. Locate the cast iron return manifold with
injector nipple (installed). Apply thread sealant to 2" NPT male threads. Insert injector nipple
16
into 2" NPT upper rear tapping on rear section, engage 2" NPT male threads on end of manifold and hand tighten.
Note: Based on system return piping and access
to service boiler, see Figure 1 and Figures 13A and 13B, predetermine if manifold orientation is to be positioned for vertical, horizontal left or horizontal right side return piping as shown in Figure 9.
Place a wrench on the hex nut portion and
tighten manifold until the return pipe orientation is correct for your installation and the joint is water tight.
Step b. Install relief valve using 3/4" NPT tapping
on side of return manifold. Relief valve must be installed in vertical position. If orientation of return manifold is for:
1-1/2" NPT vertical return piping - Install 3/4" NPT x 90° street ell (not furnished) into either the left or right side tapping on return manifold. Install relief valve vertically into street ell. Install 3/4" pipe plug (not furnished) in tapping on opposite side (see Figure 9).
1-1/2" NPT horizontal left or right side return piping - Install relief valve vertically in 3/4" NPT tapping located on top of return manifold. Install 3/4" pipe plug (not furnished) in bottom tapping as shown (see Figure 9).
Step c. Pipe discharge of relief valve as shown in
Figures 13A and 13B. Installation of the relief valve must be consistent with ANSI/ASME Boiler and Pressure Vessel Code, Section IV.
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5. Install drain valve and indirect water heater return piping, see Figure 10.
Step a. Apply pipe sealant to both ends of 1-1/4"
NPT x 5" lg. nipple. Thread nipple into 1-1/4" NPT lower rear tapping on rear section.
Step b. Thread 1-1/4" x 1-1/4" x 3/4" NPT tee on
opposite end of 5" lg. nipple installed in Step a.
NOTE: Based on access for servicing and
location of sewer or fl oor drain, when tightening
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Figure 9: Return Manifold and Relief Valve Assembly Details
17
these fi ttings, determine if drain valve is to be located on the left or right side.
Tighten nipple and tee into 1-1/4" NPT lower
rear tapping on rear section until joints are water tight for desired position.
Step c. Apply sealant to 3/4" NPT thread on drain
valve. Thread into 3/4" NPT tapping on side outlet of tee. Use hex nut portion to tighten valve until water tight.
Step d. If Alliance ™ Indirect Water Heater is
connected to system, do not install 1-1/4" NPT pipe plug. Connect piping as shown in Figures 13A, 13B, 15A and 15B, as applicable. Also refer to Alliance ™ manual for additional information.
6. Connecting fi eld wiring, refer to Figures 5, 6 and 19.
Step a. 120 volt power supply fi eld wiring will
enter internal junction box through 7/8" dia. knockout in jacket rear panel, see Figure 5.
Step b. Locate the black and white harness wires
labeled "120V Power Supply" inside internal junction box, see Figure 6. Using wire nuts, connect the 120 volt power supply fi eld wires to the harness wires. Connect the fi eld ground wire to the green grounding screw located in bottom of internal junction, refer to Figures 6 and 20.
Step c. 24V thermostat fi eld wiring will enter
internal junction box through 5/16" snap bushing
located on rear panel adjacent to 7/8" dia. knockout for power supply.
Step d. Locate the two (2) brown wires labeled
"24V Thermostat" inside the internal junction box, see Figure 6 (these wires originate from "T-T" terminals in aquastat control and feed into J-box through harness). Using wire nuts, connect 24 volt fi eld thermostat wires to brown wires in J-box.
Step e. Locate jacket top rear panel that was
removed earlier to gain access to internal junction box. Position panel between side panels, hold on a slight angle, engage tabs on front fl ange of top rear panel with rectangle slots on rear fl ange of top panel, refer to Figures 5 and 9.
NOTE: It may be necessary to lift up slightly
on top panel near slotted opening at supply manifold to align tabs with rectangular slots on anges.
Lower rear fl ange of jacket top rear panel down
over rear panel. Align holes and secure with two (2) #8 x 1/2" lg. sheet metal screws.
7. Installing stainless steel fl ueway baffl es. Baffl e requirements differ from model to model, see Table 2.
NOTE: Read caution statement before proceeding.
Figure 10: Piping Arrangement for Drain Valve and Indirect Water Heating Return
18
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8. Close the burner swing door and securely seal the
door to the boiler front section by reinstalling the hardware and securing the door using procedure previously outlined in Paragraph D of this section.
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9. Install oil burner, refer to Figure 12.
Step a. Open burner carton and remove contents. Step b. Check oil nozzle in burner for size, angle
and type, inspect electrode settings, check head setting, check air band and air shutter settings, refer to Table 6 at rear of this manual.
Step c. Place oil burner gasket on burner and align
holes.
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Step a. Install stainless steel baffl es provided in
miscellaneous parts carton as follows, refer to Table 2 and Figure 11:
Model MPO84 - To install fl ueway baffl e in 3rd pass on left side of boiler, hold baffl e with word "Left" readable at the top. Slide baffl e in fl ueway until position tab touches ns on left side of 3rd pass fl ueway. To install fl ueway baffl e in 3rd pass fl ueway on right side of boiler, hold baffl e with word "Right" readable at the top. Slide baffl e in ueway until position tab touches fi ns on right side of 3rd pass fl ueway.
Models MPO147, MPO189 and MPO231
- T o install fl ueway baffl e in 2nd pass fl ueway on left side of boiler, hold baffl e with word "Left" readable at the top. Slide baffl e in ueway until position tab touches fi ns on right side of 2nd pass fl ueway. To install ueway baffl e in 2nd pass fl ueway on right side of boier, hold baffl e with word "Right" readable at the top. Slide baffl e in fl ueway until position tab touches fi ns on left side of 2nd pass fl ueway.
NOTE: 2nd and 3rd pass fl ueway baffl e are not
interchangable.
Figure 11: Baffl e Orientation in Flueways
19
Step d. Remove three (3) 5/16-18 x 3/4 lg. cap
screw from burner swing door used for mounting burner.
Step e. Thread (1) 5/16-18 x 3/4 lg. cap screw,
approximately three (3) full turns, into tapping located at 12:00 o'clock on burner swing door.
Step f. Insert oil burner into the opening of burner
swing door. Align and engage keyhole slot in burner fl ange over head of protruding cap screw
installed in previous Step. Rotate burner to the right to lock fl ange behind head of cap screw.
Step g. Align holes and install two (2) remaining
cap screws. Level burner and fully tighten all three (3) screws.
Step h. Plug burner power cord into power outlet
receptacle located in lower right corner of front panel.
20
Figure 12: Oil Burner Installation
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