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

Page 1
DNAGNITAREPO,NOITALLATSNI
ROFSNOITCURTSNIECIVRES
OPM
RELIOBLIOSSAP-3
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).
®
Partner,
®
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100103-01R3-10/05
Price - $3.00
Page 2
IMPORTANT INFORMATION - READ CAREFULLY
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SRELIOBASU
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The following terms are used throughout this manual to bring attention to the presence of hazards
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ehthtiwecnadroccaniedamebllahsadanaCnidellatsnisreliobnogniriwllA
of various risk levels, or to important information concerning product life.
REGNAD
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2
ECITON
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Page 3
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3
Page 4
GNINRAW
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4
Page 5
STNETNOCFOELBAT
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5
Page 6
6
Figure 1: MPO 84 Thru MPO 231 Water Boiler
Page 7
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741OPM"8/5-22"42"680.1192.02545
relioB
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
.1:
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TABLE 1B: RATING DATA
.oNledoM
741OPM50.17419212116 8X8510.78
relioB
48OPM06.04847466 8X8510.78
132OPM56.11323027717 8X8510.78
981OPM53.19817615417 8X8510.78
7
Page 8
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.
Page 9
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
Page 10
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
Page 11
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
Page 12
Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)
12
Page 13
(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
Page 14
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
Page 15
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
Page 16
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.
Page 17
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
Page 18
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
Page 19
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TABLE 2: BAFFLE USAGE
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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
Page 20
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
Page 21
SECTION III: WATER BOILER PIPING
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A. EVALUATE THE EXISTING WATER
SYSTEM.
Design a piping system and install boiler which will
prevent oxygen contamination of boiler water and frequent water additions.
1. There are many possible causes of oxygen contamination such as:
a. Addition of excessive make-up water as a result
of system leaks. b. Absorption through open tanks and fi ttings. c. Oxygen permeable materials in the distribution
system.
2. In order to insure long product life, oxygen sources must be eliminated. This can be accomplished by taking the following measures:
a. Repairing system leaks to eliminate the need for
addition of make-up water. b. Eliminating open tanks from the system. c. Eliminating and/or repairing fi ttings which allow
oxygen absorption. d. Use of non-permeable materials in the
distribution system. e. Isolating the boiler from the system water by
installing a heat exchanger.
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B. CONNECT SYSTEM SUPPLY AND RETURN
PIPING TO BOILER. See Figures 13A and 13B.
Also, consult I=B=R Installation and Piping Guides.
1. If this boiler is used in connection with refrigeration systems, the boiler must be installed so that the chilled medium is piped in parallel with the heating boiler using appropriate valves to prevent the chilled medium from entering the boiler. See Figure 14. Also, consult I=B=R Installation and Piping Guides.
2. If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air, the boiler piping must be equipped with fl ow control valves to prevent gravity circulation of boiler water during the operation of the cooling system.
3. If boiler is used with an Alliance™ Indirect-Fired Domestic Water Heater, install the Alliance™ as a separate heating zone. Refer to the Alliance™ Installation, Operating, and Service Instructions for additional information.
4. Use a boiler bypass if the boiler is to be operated in a system which has a large volume or excessive radiation where low boiler water temperatures may be encountered (i.e. converted gravity circulation system, etc.) The bypass should be the same size as the supply and return lines with valves located in the bypass and return line as illustrated in Figures 13A and 13B in order to regulate water fl ow for maintenance of higher boiler water temperature.
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If a low water cut-off is required, it must be
mounted in the 3/4" supply manifold tapping (see Figures 7, 13A and 13B) or in the system piping above the boiler. The minimum safe water level of a hot water boiler is just above the highest water containing cavity of the boiler; that is, a hot water boiler must be full of water to operate safely.
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5. If it is required to perform a long term pressure test of the hydronic system, the boiler should rst
be isolated to avoid a pressure loss due to the escape of air trapped must fi rst be removed from the boiler.
21
Page 22
22
Figure 13A: Water Boiler Piping for Circulator Zoned Heating System - Supply Side Circulator
Page 23
Figure 13B: Preferred Water Boiler Piping for Zone Valve Zoned Heating System - Supply Side Circulator
23
Page 24
To perform a long term pressure test including the
boiler, ALL trapped air must fi rst be removed from the boiler.
A loss of pressure during such a test, with no visible
water leakage, is an indication that the boiler contained trapped air.
Figure 14: Recommended Piping for Combination Heating and Cooling (Refrigeration) System
24
Page 25
SECTION IV: INDIRECT WATER HEATER PIPING
A. CONNECT ALLIANCE™ INDIRECT WATER
HEATER PIPING as shown in Figures 15A and
15B.
Also refer to Figures 13A and 13B.
1. Refer to Alliance™ manual for additional information.
Figure 15A: Alliance™ Water Heater Piping w/Supply Side Circulator
on Circulator Zoned Heating System
Figure 15B: Alliance™ Water Heater Piping w/Supply Side Circulator on Zone Valve Zoned Heating System
25
Page 26
SECTION V: VENTING
A. CHIMNEY VENTING
1. Chimney venting is an important part of a safe and effi cient oil fi red appliance system. Contact your local fi re and building offi cials on specifi c requirements for restrictions and the installation of fuel oil burning equipment. In addition, consult with a professional knowledgeable on the requirements of NFPA 31 – Standard for the Installation of Oil-Burning Equipment and NFPA 211 - Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances for installations in the United States. Installations in Canada must be reviewed with a professional knowledgeable on the requirements of CSA B139-04 – Installation Code for Oil-burning Equipment.
2. The safe venting of oil fi red boilers is dependant on many factors. Some of these factors include:
a. suffi cient draft during the entire heating season
to allow for the safe discharge of combustion by­products and;
b. suitable corrosion protection in the event of
condensing fl ue gases. Only a trained and qualifi ed contractor may install this product.
3. The MPO can be vented into a fi reclay tile-lined masonry chimney that meets requirements outlined in Paragraph 4 below. It can also be vented into a chimney constructed from type L vent or a factory built chimney that complies with the type HT requirements of UL 103. The chimney and vent pipe shall have a suffi cient draft at all times, to assure safe proper operation of the boiler. See Figure 16 for recommended installation.
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4. Chimney Inspection – Prior to the installation of any new or replacement fuel burning equipment the chimney shall be inspected by a qualifi ed installer. The chimney shall be inspected for integrity as well as for proper draft and condensate control. Some jurisdictions require the use of a liner when changing fuel types. Some jurisdictions require the use of a liner even when the same fuel is used. At a minimum, the chimney shall be examined by a qualifi ed person in accordance with the requirements of Chapter 11 of NFPA 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel­Burning Appliances.
26
a. Loose Mortar – Loose mortar could be an
indication of a prior history of condensing fl ue gases upon the inside walls of the chimney. Colder climates are more susceptible to this condition. Under no circumstances shall a chimney of this condition be used until it meets the requirements of NFPA 211 or CSA B139-
04.
b. Unlined Chimney – Under no circumstances
shall a chimney constructed of brick only be used. Only approved clay liners or listed chimney lining systems shall be used as specifi ed in NFPA 31 or CSA B139-04.
c. Abandoned Openings – Openings through the
chimney wall that are no longer used shall be sealed in accordance to NFPA 211. Often abandoned openings are improperly sealed and usually covered by a gypsum wall covering.
d. Clean Chimney – Chimney shall be free of all
loose debris.
5. Draft Regulator – the draft regulator supplied with the boiler must be used with this appliance. No other draft regulator shall be used. Refer to Figures 16 and 17.
B. CHIMNEY CONNECTOR
1. A chimney connector (vent pipe) is used to connect the boiler to the base of the chimney. The chimney connector should be kept as short as possible. The horizontal length of the chimney connector shall not be greater than 10 feet.
NOTE: Secure chimney connector to cast iron
smokebox collar with three (3) #10 x ½" self drilling hex head TEK screws provided in miscellaneous parts carton. Locate screws around perimeter of
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connector as shown in Figure 16 and approximately ½" in from edge. Use drill with 5/16" hex bit to drive screws through connector and smokebox collar.
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Page 27
Figure 16: Recommended Vent Pipe Arrangement and Chimney Requirements
Figure 17: Proper and Improper Locations of Draft Regulator
27
Page 28
2. Type B Chimney Connector - a type B chimney connector can be used to transmit the fl ue gases provided fl ue gas temperature entering the chimney connector is greater than 310°F.
3. Type L Chimney Connector - a type L vent or other suitable material shall be used for a chimney connector if the temperature or exiting temperature is less than 310°F.
2. NFPA 31 and CSA B139-04 have information to help the installer make an appropriate choice of venting materials. In some cases a chimney may have to be lined to create suffi cient draft. In other cases, the chimney may have to be lined to prevent the corrosion of a masonry chimney. Consult with a chimney specialist knowledgeable on the requirements for chimney requirements in your area.
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C. DRAFT
1. The natural draft generated through a chimney is dependent on several factors including, chimney height, temperature of fl ue gases, cross section area of chimney, chimney wall insulation value, dilution air and total volume of fl ue gases, to name a few. Make sure that the boiler has been running for at least 5 minutes before measuring the draft.
2. Minimum Draft at Breech (Canopy) – The draft induced by a chimney must create at least a pressure of 0 (zero) inches water column (“ w.c.) at the pressure tapping on the canopy mounted on rear of boiler (see Figure 18). The pressure at the canopy cannot be positive since this could create a condition that allows fl ue gas by-products to escape from the draft regulator. A negative pressure reading up to -.03 inches water column is acceptable for proper operation. (See Table 6, Burner Specifi cations at the rear of this manual for more details)
3. Minimum Overfi re Pressure – The overfi re pressure is another piece of information that is often measured, however this should be done for observation purposes only! The breech pressure must be used to qualify the draft condition. See Table 6 for more details as a guide. Actual draft and temperature measurements may be different then those values in the table.
D. STACK TEMPERATURE
1. The temperature of the fl ue gases has a signifi cant effect on the amount of draft created in a vertical chimney as well as the propensity to create condensate. The higher the stack temperature, the greater the amount of draft that can be generated. A lower stack temperature not only reduces the amount of draft that can be created but it also increases the possibility that the fl ue gases could condense in the chimney connector or stack.
28
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3. Baffl es – The effi ciency of the boiler is based on the insertion of fl ue baffl es supplied with your product. Under no circumstances are other baffl es to be used on this product. The baffl es are installed in the 2nd pass (two inner fl ueways) on the MPO147, MPO189 and MPO231. The baffl es on the MPO84 are installed in the 3rd pass only. Refer to Section II, Item F, Paragraph 7 for baffl e installation. If there is any doubt on the application of this boiler on the intended chimney, consult with your local code offi cials. At a minimum, remove the baffl es to increase the stack temperature. See Table 6 for temperature differential (T) with baffl es IN and OUT. In addition, the lower the CO2 level the higher the stack temperature.
Figure 18: Smokebox Pressure Tapping for
Checking Draft at Breech
Page 29
1. General
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a. Use 4" dia., single wall galvanized metal pipe
and fi ttings available at most heating distributors for air intake piping. Maximum allowable air intake length is 50 equivalent feet. Each elbow is equal to 6 equivalent feet.
E. MINIMUM CLEARANCES
See Figure 2 for details regarding clearances to
combustibles for the boiler.
F. OPTIONAL AIR INTAKE PIPING
INSTALLATION - All air for combustion can be
supplied directly to the burner from outdoors providing that the criteria for chimney, vent connector and minimum stack temperature outlined in this section can be maintained. (ONLY AVAILABLE WITH BECKETT BURNER). See Figure 19.
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b. Start at burner. Work toward air intake terminal. c. Maintain minimum of 1/4 inch per foot slope in
horizontal run to air intake terminal. Slope down toward air intake terminal.
d. Seal all joints gas-tight, using silicone caulk or
self-adhesive aluminum tape.
2. After determining location, cut a hole in the wall to accept 4 inch air intake pipe. See Figure 19.
3. Remove the metal knockout in right side of burner cover. Install Burnham Inlet Air Accessory Kit, Part
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Number 611280031.
4. Mount the Vacuum Relief Valve Tee Assembly (P/N 8116268 included with Kit) or 90° elbow into the burner inlet ring. See Figure 18.
a. Secure with at least three (3) sheet metal screws
evenly spaced around the burner inlet ring.
b. Assemble the vacuum relief valve balance
weight onto the gate. Refer to the vacuum relief valve manufacturer's instructions.
Figure 19: Optional Air Intake Piping Installation - Only Available with Beckett Burner
29
Page 30
c. Mount the vacuum relief valve into the tee and
fasten with a screw and nut in collar tabs. To ensure proper operation, the gate must be level across the pivot point and plumb. Refer to vacuum relief valve manufacturer's instructions.
5. Install remainder of air intake, securing each joint with at least three (3) sheet metal screws evenly spaced.
6. Install air intake terminal. See Figure 19.
ECITON
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.noitalumuccawonssulpedargevoba
7. Seal all external joints with weatherproof caulk.
GNINRAW
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elitalov,stnegreted,s'CFC,setallitsid
.tneserperaslacimehcrehtoynarosropav
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.tluser
30
Page 31
SECTION VI: ELECTRICAL
REGNAD
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w
.ffodenrutsirewopecnokcoldaphti
GNINRAW
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.mrah
.krowlacirtceleynagnitpmetta
A. GENERAL
1. Install wiring and electrically ground boiler in accordance with requirements of the authority having jurisdiction, or in absence of such requirements the National Electrical Code, ANSI/ NFPA 70, and/or the CSA C22.1 Electric Code.
2. Refer to National Electric Code or Local Electric Codes for proper size and type of wire required. Follow Code.
3. A separate electrical circuit must be run from the main electrical service with an over-current device/disconnect in the circuit. A service switch is recommended and may be required by some local jurisdictions.
4. Use anti-short bushings on all wiring passing through boiler jacket, junction boxes and/or control boxes.
5. Use armored cable (BX) over all exposed line voltage wiring.
laerusekaM.ecruosenonahterommorfebyamrewoplacirtcelE
ylreporpahtiwdetcetorpebtsumreliobhcaE
6. If an Alliance™ indirect water heater is used, use priority zoning. Do not use priority zoning for Hydro-Air Systems.
7. Wiring should conform to Figure 20.
B. INSTALL A ROOM THERMOSTAT on an
inside wall about four feet above fl oor. Never install thermostat on an outside wall or where it will be infl uenced by drafts, hot or cold water pipes, lighting xtures, television, rays of the sun or near a fi replace. Keep large furniture away from thermostat so there will be free movement of room air around this control.
Heat Anticipator in Thermostat should be set to match
the requirements of the control to which it is connected. See Figure 20 for desired system and heat anticipator setting. If system tends to overheat above the thermostat's temperature setting, reduce heat anticipator setting by .1 or .2 amps. If system tends to short cycle without reaching desired room temperature, increase heat anticipator setting by .1 or .2 amps.
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.slortnocgnitareporoytefasynaevitareponiekamrotuopmujreveN
erofebffosirewopl
31
Page 32
32
BOILER SEQUENCE OF OPERATION
Figure 20: Schematic Wiring Diagram, Standard Control Set w/Optional LWCO and/or High Limit Accessory Kit
A call for heat by the thermostat energizes the L7248C control which in turn energizes the primary control to turn on the burner. The burner will operate in the following sequence:
operate as long as the thermostat is calling for heat. If the thermostat is not satisfi ed and the operating (high) limit is reached, the circulator will continue to operate, and the burner will stop
until the operating (high) limit is closed by a 15°F drop in boiler water temperature.
On water boiler equipped with Optional L4080B Auxiliary High Limit Control, if boiler water temperature exceeds the operating limit setting and reaches the high limit setting, the circulator
will continue to operate, and the burner will stop until the high limit is closed by an 8°F drop in boiler water temperature.
Prepurge for the fi rst 10 seconds; fi re until the thermostat is satisfi ed or the limit setting on the operating (high) limit is reached; post-purge for the last 10 seconds. The circulator will
On burner start, if the cad cell does not see fl ame within approximately 15 seconds, primary control will shut burner down and enter into a recycle mode, after 60 seconds burner will restart
and repeat trial for ignition. If after three (3) trials for ignition, fl ame is not detected, control will enter into restricted mode and must be reset manually before burner can be restarted.
On water boiler equipped with optional low water cut-off (LWCO) control, if probe senses a low water condition, power to the L7248C control is de-energized. When water level is
replenished, LWCO will automatically re-energize sending power to the L7248C control.
Page 33
SECTION VII: OIL PIPING
A. GENERAL
1. Use fl exible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping.
2. A supply line fuel oil fi lter is recommended as a minimum for all fi ring rates but a pleated paper fuel oil fi lter is recommended for the fi ring rates below
1.0 gph to prevent nozzle fouling.
3. Use Flared fi ttings only. Cast iron fi ttings cannot be used.
ECITON
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4. Use of a high effi ciency micron fi lter (Garber or equivalent) in addition to a conventional fi lter is highly recommended.
5. Piping used to connect the oil burner to the oil supply tank shall not be smaller than 3/8" iron pipe or 3/8" OD copper tubing. Copper tubing shall have a .032" minimum wall thickness.
GNINRAW
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ECITON
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snoitcidsirujemos,noitiddanI.renrub
lacirtceleelbisufafoesuehteriuqer
kcehC.tiucricrenrubehthtiwkcolretni
.stnemeriuqerlaicepsrofsedoClacolruoy
B. SINGLE PIPE OIL LINES
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rof40-931BASCdnasetatSdetinUeht
1. Standard burners are provided with single-stage 3450 rpm fuel units with the bypass plug removed for single-pipe installations.
2. The single-stage fuel unit may be installed single­pipe with gravity feed or lift. Maximum allowable lift is 8 feet. See Figure 21.
3. Fuel Oil Line Deaerator – On many occasions a leaky oil delivery line can introduce air into the fuel oil supply system. This often creates a rough starting condition and can create a burner lockout state. In addition to fi xing the leak, a fuel line deaerator can be installed to eliminate air. The single line from the fuel tank is connected to the deaerator. The burner pump must be connected to the deaerator as a two pipe system. Follow the oil pump manufacturer’s recommendations for conversion to a two pipe system.
Figure 21: Single Pipe Oil Line
33
Page 34
C. TWO PIPE OIL LINES
1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 3 (two-stage) and Table 4 (single-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch OD tubing for both suction and return lines. Refer to Figure 22.
2. Follow the oil pump manufacturer’s recommenda­tions on the proper connections for a two pipe system. Some manufacturers require the insertion of a bypass plug.
3. Under no circumstances is a manual shutoff valve to be located on the return line of a two pipe system. Accidental closure of the return line will rupture the oil pump seals.
TABLE 4: SINGLE-STAGE UNITS (3450 RPM) - TWO PIPE SYSTEMS
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TABLE 3: TWO-STAGE UNITS (3450 RPM) - TWO PIPE SYSTEMS
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'2'58'001
'4'77'001
'6'96'001
'8'06'001
'01'25'001
'21'44'001
'41'63'001
'61'72'001
'81---'67
'0'48'001
'1'87'001
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'3'86'001
'4'36'001
'5'75'001
'6'25'001
'7'74'001
'8'24'001
'9'63'001
'01'13'001
'11'62'001
'21'12'38
'31---'26
'41---'14
34
Figure 22: Two Pipe Oil Lines
Page 35
SECTION VIII: SYSTEM START-UP
GNINRAW
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.tekcajtnorfehtnielcatpecerehtmorfdetcennocsidebotevahlliwdrocrewoprenrub
A. ALWAYS INSPECT INSTALLATION
BEFORE STARTING BURNER.
1. Verify that the venting, water piping, oil piping, and electrical system are installed properly. Refer to Installation Instructions contained in this manual.
2. Confi rm all electrical, water and oil supplies are turned off at the source and that the vent is clear from obstructions.
GNINRAW
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.putratsgnitpmetta
B. FILL HEATING SYSTEM WITH WATER.
ECITON
lioehtevomerylreporpottnatropmisitI
naelcoteruliaF.metsysehtmorftriddna
yseht
CLEAN HEATING SYSTEM if boiler water is
dirty.
Refer to Maintenance and Service Instructions Section
of this manual for proper cleaning instructions for water boilers.
1. HOT WATER BOILERS. Fill entire heating system with water and vent air from system. Use the following procedure on a series loop or multi­zoned system installed as per Figures 13A and 13B, to remove air from system when fi lling: a. Close full port ball valve in boiler system piping.
b. Isolate all zones by closing zone valves or shut-
off valves in supply and return of each zone(s).
c. Attach a hose to vertical purge valve in boiler
system supply piping up stream from the full port ball valve.
(Note - Terminate hose in fi ve gallon bucket at a
suitable fl oor drain or outdoor area).
d. Starting with one zone at a time, open zone valve
or shut-off valve in boiler supply and return piping.
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e. Open purge valve. f. Open shut-off valve in cold water supply piping
located between the air scoop and expansion tank.
g. Allow water to overfl ow from bucket until
discharge from hose is bubble free for 30 seconds.
h. When zone valve is completely purged of air,
close zone valve or shut-off valve. Open zone valve to the next zone to be purged. Repeat this step until all zones have been purged. At completion, open all zone valves.
i. Close purge valve, continue fi lling the system
until the pressure gauge reads 12 psi. Close shut­off valve in cold water supply piping.
GNINRAW
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j. Open full port ball valve in boiler system piping. k. Remove hose from purge valve. l. Confi rm that the boiler and system have no water
leaks.
m. It may be necessary to clean the air vent
assembly after a few days of operation.
C. CHECK CONTROLS, WIRING AND
BURNER to be sure that all connections are tight and
burner is rigid, that all electrical connections have been completed and fuses installed, and that oil tank is fi lled and oil lines have been tested.
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35
Page 36
D. ADJUST CONTROL SETTINGS with burner
service switch turned “ON” and room thermostat set 10° below room temperature.
1. Adjustment and display modes of the L7248C Oil
Electronic Aquastat Controller. a. On the L7248C, the overall range of the High
Limit is from 180°F to 240°F (82°C to 116°C).
b. Set the High Limit (designated HL) on the
L7248C Aquastat Control at 180°F. This temperature setting may be varied to suit requirements of installation. Differential is fi xed at 15°F.
i. Adjusting Settings: To discourage unauthorized changing of
Aquastat settings, a procedure to enter the adjustment mode is required. To enter the adjustment mode, press the UP, DOWN, and I buttons (see Figure 23) simultaneously for three (3) seconds. Press the ‘I’ button until the feature requiring adjustment is displayed:
· High Limit
· °F -- °C (Toggle) Then press the UP and/or DOWN buttons
to move the set point to the desired value. After 60 seconds without any button inputs, the control will automatically return to the READ mode.
any key pressed, the display will enter a dim display mode. To return to the bright display mode, simply press any key.
Text Description Display
Shows
bt Boiler Temperature
HL High Limit err Error Code f Degrees Fahrenheit c Degrees Celsius
Figure 24: Display Readout Defi nitions
2. Control Operating Characteristics The L7248C can be in any three (3) operational
states: Normal, High-Limit and Error. The controller moves back and forth from High-Limit to Normal state as part of normal operation.
The controller will enter the Error state when there
is an abnormal condition. The operating states are: a. Normal: Boiler temperature has gone below the
high limit setting (minus the differential) and has not exceeded the high limit setting.
b. High-Limit: Boiler temperature has gone above
the high limit setting and has not dropped below the high limit setting (minus the differential).
c. Error: The controller has detected an error
condition (e.g., open sensor) and has shut down the burner output. The controller continues to monitor the system and automatically restarts if the error condition clears. See Table 5.
Figure 23: L7248C Circuit Board Layout -
Horizontal Mount
ii. Display:
In the RUN mode, the Aquastat will fl ash
“bt” (boiler temp.) followed by the temp­erature (i.e., 220), followed by °F or °C.
To read boiler settings, press the ‘I’ key to
read the parameter of interest. For example, press I (HL) High Limit is displayed, followed by a three-digit number, i.e., 220, followed by °F or °C. See Figure 24 for Display Readout Defi nitions.
After approximately 60 seconds without
36
TABLE 5: LED ERROR CODES
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2rrE.gniriwMOCarivnEkcehc;tluafMOCE
3rrE.lortnocecalper;tluaferawdraH
d. The operating sequence for L7248C is described
below and shown in Table 6.
The switching action in the L7248C control
has one setting, the high limit, see Figure 25. The switching relay is controlled by the low voltage room thermostat. On a call for heat, the relay contacts make to complete the line voltage circulator circuit and also the burner circuit if the boiler water temperature is below the high limit setting. The high limit switch shuts off the burner if boiler water temperature exceeds the high limit setting. The circulator will continue to operate as long as the thermostat is calling for heat. The
noitcA/esuaC
Page 37
high limit automatically resets after the water temperature drops past the setpoint and through the differential.
Figure 25: L7248C Setpoint and Differential
Switching Action
TABLE 6: L7248C CONTROLLER OPERATING
SEQUENCE
noitcAesnopseRmetsyS
3. TURN ‘ON’ BURNER service switch and allow burner to run until oil fl ows from vent tting in a SOLID stream without air bubbles for approximately 10 seconds.
NOTE: For Primary Control "Pump Priming
Cycle" details, see Paragraph I, No. 2., Step a., Item ii .
4. Close vent fi tting and burner fl ame should start immediately after prepurge is completed. Prepurge prevents burner fl ame until 15 seconds has elapsed after initial power is applied to burner. During prepurge the motor and igniter will operate but the oil valve will remain closed. Refer to Oil Primary Control Instructions for more details.
5. Adjust oil pressure. a. When checking a fuel unit's operating pressure, a
reliable pressure gauge may be installed in either the bleeder port or the nozzle port. See Figure
26.
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.ffonrutrenrubdnarotalucriC
.detcerrocsirorre
.snoitcennocehtninoisorroc
E. ADJUST OIL BURNER BEFORE
STARTING.
1. CHECK BURNER AIR BAND, AIR SHUTTER AND HEAD SETTING (if applicable), readjust if necessary, see Table 8 at rear of manual.
2. OPEN ALL OIL LINE VALVES.
3. Attach a plastic hose to fuel pump vent fi tting and provide a pan to catch the oil.
4. OPEN FLAME OBSERVATION PORT COVER on burner swing door.
F. START OIL BURNER.
1. Open vent fi tting on fuel pump.
2. PRESS RED RESET BUTTON on front of burner cover, hold for one (1) second and release to reset primary control.
renruB.dekcehcsierutarepmetrelioB sierutarepmetretawehtnehwstratser
nehwstratserrenruB.ffodenrutsirenruB
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.laitnereffidehtsunimgnittestimilhgih
stuptuolla,detcetedsinoitidnocrorrenafI
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nehwstratserdnanoitcnufotseunitnoc
eht,ecneuqeskcehcrorreehtgniruD
dnarosnesehtnitfirdrofskcehcmetsys
Figure 26: Adjusting Fuel Pump Pressure
b. Locate oil pressure adjusting screw and turn
screw to obtain proper pump pressure, refer to Table 8 at rear of manual.
c. To check the cut-off pressure, deadhead a reliable
pressure gauge onto the copper connector tube attached to the nozzle port. Run the burner for a short period of time. Shut the burner off. The pressure should drop and hold.
d. Remove the gauge and install bleeder port and/or
reconnect the nozzle port line.
G. ADJUST OIL BURNER WHILE
OPERATING. ( ame present)
1. ADJUST DRAFT REGULATOR for a draft of zero inches (water gauge) in the canopy (see Figure
18) after chimney has reached operating temperature and while burner is running. (At least fi ve minutes)
See Table 8 at rear of manual for details.
2. READJUST THE AIR BAND on burner for a light orange colored fl ame while the draft in the canopy is zero inches water column ("w.c.). Use a
37
Page 38
38
Figure 27: "L1/L2" and "V1" Head Electrode Positioning and Gun Setting (Beckett AFG)
Page 39
smoke tester and adjust air for minimum smoke (not to exceed #1) with a minimum of excess air. Make nal check using suitable instrumentation to obtain a CO2 of 11.5 to 12.5% with draft of zero inches water column ("w.c.) (water gauge) in canopy. These settings will assure a safe and effi cient operating condition. If the fl ame appears stringy instead of a solid fi re, try another nozzle of the same type. Flame should be solid and compact. After all adjustments are made recheck for a draft of zero inches water column ("w.c.) in the canopy. Replace plug at completion.
See Table 8 (at rear of this manual) for details
regarding the overfi re pressure when baffl es are both installed and removed.
3. READJUST THE HEAD SETTING only if necessary.
a. MPO84 & MPO147: Beckett MB(L1 & L2) Head burners have a fi xed
head which are non-adjustable.
b. MPO189 & MPO231: Beckett MD(V1) (variable) Head burners have
the ability to control air by moving the head. It might be necessary to move the head forward or back one position at a time to optimize the smoke and CO
4. TURN “OFF” BURNER and remove pressure gauge. Install gauge port/bleeder plug and tighten. Start burner again.
readings. See Figure 27.
2
2. IF NOZZLE CONTINUES TO DRIP, repeat Paragraph H, No. 1. If this does not stop the dripping, remove cut-off valve and seat, and wipe both with a clean cloth until clean, then replace and readjust oil pressure. If dripping or after burn persist replace fuel pump.
I. TEST CONTROLS.
1. Check thermostat operation. Raise and lower thermostat setting as required to start and stop burner.
GNINRAW
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2. VERIFY PRIMARY CONTROL FEATURES using procedures outlined in Instructions furnished with control or instructions as follows:
a. FEATURES AND CONTROLS
i. The R7184 is a microprocessor-based
control. The indicator light provides diagnostic information for lockout, recycling and patented cad cell status. There is a manual reset button to exit the Lockout Mode and enter the Idle Mode (see Figure
28).
GNINRAW
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5. FLAME FAILURE The MPO boiler controls operate the burner
automatically. If for unknown reasons the burner ceases to fi re and the reset button on the primary control has tripped, the burner has experienced ignition failure.
GNINRAW
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H. CHECK FOR CLEAN CUT OFF OF
BURNER.
1. AIR IN THE OIL LINE between fuel unit and nozzle will compress when burner is on and will expand when burner stops, causing oil to squirt from nozzle at low pressure as the burner slows down and causing nozzle to drip after burner stops. Usually, cycling the burner operation about 5 to 10 times will eliminate air from the oil line.
sgnittifenillioynaevomerronesooltonoD
Figure 28: R7184 Terminals, LED and Reset Button
ii. Pump Priming Cycle: To facilitate purging
air from the oil lines and fi lters, the R7184 can be placed in a purge routine by pressing and releasing the reset button during the
nehwrenrubehttratsottpmettatonoD
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safety check, delayed valve-on, ignition or carry-over periods.
iii. Limited Recycle: This feature limits the
number of recycle trials (for each call for heat) to a maximum of three trials. If the fl ame is lost three times and does not successfully satisfy a call for heat, the R7184 locks out.
iv. Limited Reset (Restricted Mode): In order
to limit the accumulation of unburned oil in the combustion area, the control can only be reset three times. The reset count returns to zero each time a call for heat is successfully completed.
39
Page 40
To reset from Restricted Mode: Press and
hold the reset button for 30 seconds. When the LED fl ashes twice, the device has reset.
v. T-T Jumper: Select models have pre-
installed T-T jumper resistor. To remove jumper, if applicable, use side-cutting pliers to cut jumper (See Figure 28).
vi. Diagnostic LED: The indicator light on oil
primary control provides lockout, recycle and cad cell indications as follows:
Flashing at 1 Hz (½ second on, ½ second
off): system is locked out or in Restricted Mode.
Flashing at ¼ Hz (2 seconds on, 2 seconds
off): control is in Recycle Mode.
On: cad cell is sensing fl ame.
Off: cad cell is not sensing fl ame.
vii. Cad Cell Resistance Check: For proper
operation it is important that the cad cell resistance is below 1600 ohms. During a normal call for heat, once the control has entered the Run Mode, press and release the reset button. Indicator light will fl ash 1 to 4 fl ashes. See Table 7 for equivalent cad cell resistance.
TABLE 7: CAD CELL RESISTANCE WHEN
SENSING FLAME
sehsalFsmhoniecnatsiseRlleCdaC
1004nahtsseL 2008nahtsseldna004nahteroM 30061nahtsseldna008nahteroM
40005nahtsseldna0061nahteroM
Check the oil pump pressure.
Check the piping to the oil tank.
Check the oil nozzle, oil supply and oil
fi lter. ii. Check Safety Features Safe Start:
Place a jumper across cad cell terminals.
Follow procedure to turn on burner.
Burner must not start, indicator light turns
on and control remains in Idle Mode.
Remove jumper.
iii. Simulate Ignition or Flame Failure:
Follow procedure to turn on burner.
Close hand valve in oil supply line.
Failure occurs, device enters Recycle
Mode. Indicator light fl ashes at ¼ Hz rate
2 seconds on, 2 seconds off).
Device tries to restart system after
approximately 60 seconds.
After third Recycle Mode trial, safety
switch locks out within safety switch
timing indicated on label and control
enters Restricted Mode. Indicator light
fl ashes at 1 Hz rate (½ second on, ½
second off). Ignition and motor stop and
oil valves closes.
To reset from Restricted Mode: Press and
hold the reset button for 30 seconds.
When the LED fl ashes twice, the device
has reset. iv. Cad Cell Check: See Figure 29.
40
b. CHECK OIL PRIMARY CONTROL
NOITUAC
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decneirepxe,deniartaylno,egatlov
ehtmrofrepdluohsnaicinhcetecivres
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.debircsedsa
i. Preliminary Steps
Check wiring connections and power
supply.
Make sure power is on to the controls.
Make sure limit control is closed.
Check contacts between ignitor and the
electrodes.
.skcehc
.trapatiekatottpmettatonoD.strap
elbaecivres-dleifonsniatnoclortnocsihT
tonsinoitarepofilortnoceritneecalpeR
Figure 29: Cad Cell Location
Perform cad cell resistance check as
outlined in control feature. If resistance is
below 1600 OHMS and burner runs
beyond safety cut-out time, cad cell is good.
If safety switch shuts down burner and
resistance is above 1600 OHMS, open line switch to boiler. Access cad cell under
Page 41
ignitor, clean face of cad cell and see that cell is securely in socket. Check gasket around perimeter of ignitor lid for proper seal. If gasket is missing or damaged, replace gasket. Room light can effect cad cell resistance. Reset safety switch.
Close line switch to boiler. If burner starts
and runs beyond safety switch cut-off time, cell is good. If not, install new cell.
v. Power Failure Check: After Flame is
established, turn the power off to the control/ burner. The burner should shut down safely. When power is restored a normal ignition sequence should be started.
3. WARNING — Check High Limit Control — Jumper Thermostat Terminals. Allow burner to
operate until shut-down by limit. Installation is not considered complete until this check has been made.
GNINRAW
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4. CHECK LOW WATER CUT - OFF CONTROL
TNATROPMI
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Hydrolevel 1150 probe low water cut-off operational test procedure:
a. Before raising the water level above the Model
1150, turn on power to the boiler and set the thermostat to call for heat. Both the green "POWER" LED and amber "LOW WATER" LED should illuminate. The burner should not re. IMPORTANT: If the burner fi res with no water at the probe, immediately shut down power to the boiler and refer to the Trouble Shooting instructions in manufacturer's literature provided with the control.
b. Proceed to fi ll the boiler with water. When water
reaches the LWCO position, the burner should re. If the burner does not fi re, refer to the Trouble Shooting instructions in manufacturer's literature provided with the control.
c. Turn off the power to the boiler and fi nish fi lling
the system. Lower the thermostat to desired room temperature setting.
d. Before leaving the job, power up the system
and push the TEST button on the Model 1150 to simulate a low water condition. The amber "LOW WATER" LED should illuminate and the burner should shut down.
J. IF CONTROLS DO NOT MEET
REQUIREMENTS outlined in Paragraph I.,
replace control and repeat checkout procedures.
41
Page 42
noitamrofnIytefaStcudorPtnatropmI
tcudorPrebiFcimareCyrotcarfeR
Warning: This product contains refractory ceramic fi bers (RCF). RCF has been classifi ed as
a possible human carcinogen. After this product is fi red, RCF may, when exposed to extremely high temperature (>1800F), change into a known human carcinogen. When disturbed as a result of servicing or repair, RCF becomes airborne and, if inhaled, may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures: Do not remove or replace previously fi red RCF (combustion chamber insulation,
target walls, canopy gasket, fl ue cover gasket, etc.) or attempt any service or repair work involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator
2. Long sleeved, loose fi tting clothing
3. Gloves
4. Eye Protection
Take steps to assure adequate ventilation.
Wash all exposed body areas gently with soap and water after contact.
Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
Discard used RCF components by sealing in an air tight plastic bag.
First Aid Procedures:
If contact with eyes: Flush with water for at least 15 minutes. Seek immediate medical attention if irritation persists.
If contact with skin: Wash affected area gently with soap and water. Seek immediate medical attention if irritation persists.
If breathing diffi culty develops: Leave the area and move to a location with clean fresh air. Seek immediate medical attention if breathing diffi culties persist.
Ingestion: Do not induce vomiting. Drink plenty of water. Seek immediate medical attention.
42
Page 43
SECTION IX: MAINTENANCE AND SERVICE INSTRUCTIONS
A. MAINTENANCE OF LOW WATER CUT-
OFF DEVICES (when installed)
See Section XIV Appendix for LWCO Installation
Instructions
GNINRAW
.ecnanetniamdnanoitcepsnilaunna
1. PROBE TYPE LOW WATER CUT-OFF Although these devices are solid state in their
operation, the probe is exposed to possible contamination in the boiler water and subject to fouling.
Provisions have been made on the supply manifold
on the boiler. Sometimes the LWCO can be found in the primary loop of the boiler system. Ideally, shut off valves have been installed between the loop containing the LWCO and the rest of the system, to minimize the amount of system draining.
It is important to physically remove the probe from
the lwco tapping annually and inspect that probe for accumulation of scale or sediment.
Follow these steps to inspect, clean and/or replace
the probe: a. Turn off electric service to the boiler. b. Drain boiler water to a level below the tapping
for the probe.
c. Disconnect wiring connections between the low
water cut-off control and the probe.
d. Remove the low water cut-off control from the
probe.
REGNAD
erusserporeztasireliobehttahterussA
er
ehtnepO.erusserporeztasireliobeht
.detanimilesisnrubrof
e. Unscrew the probe from the LWCO tapping. f. Inspect that portion of the probe that is exposed
to the water for a scale or sediment buildup.
g. Light deposits may be removed by wiping the
probe with a damp cloth. Wiping the probe with a cloth soaked in vinegar will remove more
tenacious lime deposits. The most stubborn deposits may be removed from the probe by using a diluted amount, 3 parts of water to 1 part of phosphoric acid (H2PO4).
NOITUAC
eriuqersecivedffo-tucretawwolepyteborP
.reniatnoc
h. Clean the pipe threads of the probe to remove
old, hardened pipe dope and other foreign matter.
i. Apply a moderate amount of good quality pipe
dope to the pipe threads on the probe, leaving the two end threads bare. Do not use PTFE (Tefl on)
tape. j. Screw the probe into the LWCO tapping. k. Mount the low water cut-off control on the
probe. l. Reconnect the control to probe wiring. m. Fill the system with water. n. Add boiler water treatment compound as needed
(refer to Paragraph B.). o. Restore electric service to the boiler. p. Fire burner to bring the water in the boiler to a
boil to drive off free oxygen. q. WARNING — BEFORE RETURNING
BOILER TO SERVICE: Follow the low water
cut-off check out procedure in Section IX,
Paragraph I, No. 4.
B. BOILER AND SYSTEM CLEANING
INSTRUCTIONS FOR TROUBLE FREE OPERATION
1. Filling of Boiler and System — General —-In a hot water heating system, the boiler and entire system
tonoD.eborpOCWLehtgnivomererofeb
tahtetacidnioteguagerusserpehtnoyl
erusserplanretnillaeveilerotevlavytefas
egrahcsidevlavytefaS.gnideecorpotroirp
laitnetopehttahthcusdepipebtsumgnipip
(other than the expansion tank) must be full of water for satisfactory operation. Water should be added to the system until the boiler pressure gauge registers 12 psi. To insure that the system is full, water should come out of all air vents when opened.
2. Boiling Out of Boiler and System. The oil and grease which accumulate in a new hot water boiler can be washed out in the following manner.
a. Ideally, shut off valves have been installed
between the boiler return manifold and the rest of the system, to minimize the amount of system draining.
b. Drain the boiler to a level below the relief valve
tapping.
cirohpsohpgnildnahnehwnoituacesicrexE
stinolebalnoitcurtsniehtwollofdnadica
43
Page 44
REGNAD
erusserporeztasireliobehttahterussA
ehtnepO.evlavfeilerehtgnivomererofeb
erusserplanretnillaeveilerotevlavytefas
egrahcsidevlavytefaS.gnideecorpotroirp
.detanimilesisnrubrof
c. Remove relief valve using extreme care to avoid
damaging it.
d. Add an appropriate amount of recommended boil
out compound. e. Replace relief valve. f. Fill the entire system with water. g. Start fi ring the boiler. h. Circulate the water through the entire system. i. Vent the system, including the radiation. j Allow boiler water to reach operating
temperature, if possible. k. Continue to circulate the water for a few hours.
l. Stop fi ring the boiler. m. Drain the system in a manner and to a location
that hot water can be discharged with safety. n. Remove plugs from all available returns and
wash the water side of the boiler as thoroughly as
possible, using a high-pressure water stream. o. Refi ll the system with fresh water.
3. Add appropriate boiler water treatment compounds as recommended by your qualifi ed water treatment company.
4. Make pH or Alkalinity Test.
After boiler and system have been cleaned and
refi lled as previously described, test the pH of the water in the system. This can easily be done by drawing a small sample of boiler water and testing with hydrion paper which is used in the same manner as litmus paper, except it gives specifi c readings. A color chart on the side of the small hydrion dispenser gives the reading pH. Hydrion paper is inexpensive and obtainable from any chemical supply house or through your local druggist. The pH should be higher than 7 but lower
than 11. Add appropriate water treatment chemicals, if necessary, to bring the pH within the specifi ed range. With this lower level of protection, care must be exercised to eliminate all of the free oxygen in the system.
5. Boiler is now ready to be put into service.
laitnetopehttahthcusdepipebtsumgnipip
C. FREQUENT WATER ADDITION Although unusual for a water boiler, frequent water
additions are a sign of a leaky system. Excessive amounts of make up water supplied to the boiler can signifi cantly shorten the life of the boiler. The amount of water varies with the contamination level of the water. Repair the leak and consult with your water treatment specialist for recommendations.
D. ATTENTION TO BOILER WHILE NOT IN
OPERATION.
ECITON
ti,emitretniwgniruddesutonsireliobfI
ezeerftneverpotdeniardyllufebtsum
.egamad
1. Spray inside surfaces with light lubricating or crankcase oil using gun with extended stem so as to reach all corners.
2. Always keep the manual fuel supply valve shut off if the burner is shut down for an extended period of time.
3. To recondition the heating system in the fall season after a prolonged shut down, follow the instructions outlined in Section IX, Paragraphs A through J.
GNINRAW
yamhcihwslortnocsniatnocreliobsihT
tondnanwodtuhsotreliobehtesuac
oteudegamadfI.ecivrestuohtiwtratser
gn
itaeheht,ytilibissopasisepipnezorf
nidednettanutfelebtondluohsmetsys
sdraugefasetairporpparo;rehtaewdloc
ehtnodellatsniebdluohssmraladna
ehtfiegamadtneverpotmetsysgnitaeh
.evitareponisireliob
44
Page 45
SECTION X: BOILER CLEANING
GNINRAW
.detelpmocsiecivresnehwyletelpmoc
deppiuqesrelioB.ffodenruthctiwsecivresrenrubhtiwdetelpmocebtsumgninaelcreliobllA
,egamadytreporperevesesuacnachcihwdrazahlaitnetopaevahroodgniwsrenrubhtiw
othctiwsecivresffonrut,roodgniwsgninepoerofeB.derongifiefilfossolroyrujnilanosrep
ehttcennocsiD.rebmahcnoitsubmocehtedistuorenrubfogniriflatnediccatneverpotreliob
renetsafroodgniwsnethgitoteruseB.tekcajtnorfehtnielcatpecerehtmorfgulprenrub
A. CLEAN THE FLUEWAYS (See Figure 30).
1. For access to the combustion chamber remove the
two (2) 3/8" - 16 cap screws. If boiler is equipped with fl exible fuel line(s), swing door open.
2. Remove the two smoke box clean-out covers from the rear smoke box by removing the four 5/16"-18 hex head bolts. It is NOT necessary to remove the vent connector from the smoke box to clean boiler.
If necessary, remove the vent connector if there is
evidence of heavy soot accumulation in the boiler or to inspect bse of chimney for condensate or accumulation of debris.
3. Remove the baffl es (if installed) from the fl ue passages. There is a pair of baffl es in each boiler. The baffl es are installed in the 3rd pass (two outer ueways) on the MPO84, and in the 2nd pass (two inner fl ue ways) on the MPO147, MPO189 and MPO231.
4. Clean the 3rd Pass – Insert a 2" dia. x 42" long wire or fi ber bristle brush into each of the two 3rd passes. Using long strokes push the brush all the way through the boiler until the brush has exited the smoke box opening. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the ue way until clean. Repeat the operation for the other 3rd pass fl ue way.
5. Clean the 2 or fi ber bristle brush into each of the two 2nd passes. Using long strokes push the brush all the way through the boiler until the brush hits the back wall of the reversing chamber. Pull the brush all the way forward until it has exited the front of the boiler. Continue this operation for the entire height of the ue way until clean. Repeat the operation for the other 2nd pass fl ue way.
6. Vacuum the loose debris in the bottom of the combustion chamber and smoke box.
B. CLEAN THE COMBUSTION CHAMBER
– Use a wire or fi ber bristle brush to clean the surfaces of the combustion chamber. Vacuum all of the loose debris in the bottom of the combustion chamber.
nd
Pass - Insert a 2" dia. x 42" long wire
C. AFTER CLEANING, vacuum all remaining debris
as necessary. Inspect burner swing door insulation, and rope gasket for signs of damage. If damaged, replace as needed.
D. REASSEMBLE BOILER.
NOITUAC
renrubehtsselnurenrubehttratstonoD
erasetalprevocyponacdnaroodgniws
.ecalpnideruces
1 Insert the baffl es (if originally installed) into the
correct fl ue way. The baffl es are installed in the 3rd pass (two outer fl ueways) on the MPO84, and in the 2nd pass (two inner fl ue ways) on the MPO147, MPO189 and MPO23.
2. Attach the smoke box clean-out covers onto the rear of the boiler. Verify that the rope gasket is in good working order before assembly. Replace rope gasket if necessary. Use the 3/8" hardware originally removed. Do not over tighten. They should be snug but not bottomed out.
ECITON
ekamroodgniwsrenrubgnirucesnehW
.sedishtobnoyllauqeni-nwardsirooderus
Tighten swing door hardware to provide adequate
seal to rope gasket around perimeter of door.
Use an alternating tightening method from right side
to left side cap screw to pull door tight equally.
ECITON
lliwteksageporehT.nethgitrevotonoD
siroodehtnehwlaestneiciffusedivorp
.ecalpotnidelgguns
45
Page 46
Figure 30: Cleaning of Boiler Flueways
GNINRAW
daniroytridaotdetcennocsireliobehtfitluserdluocegamad
ytreporpsuoireS.noitidnocdoogniyenmihcdevorppanaotdetcennocebtsumreliobehT
foroiretniehT.yenmihcetauqe
dnanosaesgnitaehehtfotratsehterofebdenaelcdnadetcepsniebtsumeulfyenmihceht
naelcA.snoitcurtsboynarofnosaesgnitaehehttuohguorhtyllacidoirepdetcepsniebdluohs
royrujniesuacdluoctahtsemufsuoixonwollaotyrassecensieulfyenmihcdetcurtsbonudna
.ycneiciffes'reliobehtgniniatniamdrawotetubirtnoclliwdnaylefastnevotefilfossol
46
Page 47
SECTION XI: TROUBLE SHOOTING
A. COMBUSTION
1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the MPO boiler is the result of extensive testing to obtain the best fl ame shape and effi cient combustion. Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO smoke. Nozzles are delicate and should be protected from dirt and abuse. Nozzles are mass-produced and can vary from sample to sample. For all of those reasons a spare nozzle is a desirable item for a serviceman to have.
2. FLAME SHAPE — Looking into the combustion chamber through the observation port, the fl ame should appear straight with no sparklers rolling up toward the crown of the chamber. If the fl ame drags to the right or left, sends sparklers upward or makes wet spots on the chamber walls, the nozzle should be replaced. If the condition persists look for fuel leaks, air leaks, water or dirt in the fuel as described above.
3. FUEL LEAKS — Any fuel leak between the pump and the nozzle will be detrimental to good combustion results. Look for wet surfaces in the air tube, under the ignitor, and around the air inlet. Any such leaks should be repaired as they may cause erratic burning of the fuel and in the extreme case may become a fi re hazard.
4. AIR LEAKS — Any such leaks should be repaired, as they may cause erratic burning of the fuel and in extreme cases may become a fi re hazard.
5. GASKET LEAKS — If 11.5 to 12.5% CO2 with a #1 smoke cannot be obtained in the breeching, look for air leaks around the burner mounting gasket, observation door, and canopy gasket. Such air leaks will cause a lower CO2 reading in the breeching. The smaller the fi ring rate the greater effect an air leak can have on CO2 readings.
6. DIRT — A fuel fi lter is a good investment. Accidental accumulation of dirt in the fuel system can clog the nozzle or nozzle strainer and produce a poor spray pattern from the nozzle. The smaller the ring rate, the smaller the slots become in the nozzle and the more prone to plugging it becomes with the same amount of dirt.
7. WATER — Water in the fuel in large amounts will stall the fuel pump. Water in the fuel in smaller amounts will cause excessive wear on the pump, but more importantly water doesn’t burn. It chills the fl ame and causes smoke and unburned fuel to pass out of the combustion chamber and clog the ueways of the boiler.
and
2
8. COLD OIL — If the oil temperature approaching the fuel pump is 40°F or lower, poor combustion or delayed ignition may result. Cold oil is harder to atomize at the nozzle. Thus, the spray droplets get larger and the fl ame shape gets longer. An outside fuel tank that is above grade or has fuel lines in a shallow bury is a good candidate for cold oil. The best solution is to bury the tank and lines deep enough to keep the oil above 40°F.
9. HIGH ALTITUDE INSTALLATIONS — Air openings must be increased at higher altitudes. Use instruments and set for 11.5 to 12.5% CO
.
2
10. START-UP NOISE — Late ignition is the cause of start-up noises. If it occurs recheck for electrode settings, fl ame shape, air or water in the fuel lines.
11. SHUT DOWN NOISE — If the fl ame runs out of air before it runs out of fuel, an after burn with noise may occur. That may be the result of a faulty cut-off valve in the fuel pump, or it may be air trapped in the nozzle line. It may take several fi ring cycles for that air to be fully vented through the nozzle. Water in the fuel or poor fl ame shape can also cause shut down noises.
ECITON
snurrenrubehtfI.ecruosrehtona
ehtfotuogniwardnehwyllufsseccus
.etisboj
B. OIL PRIMARY CONTROL
1. Burner (control) will not come on. a. No power to control. b. Control is in lockout or restricted mode. Press
reset button for one (1) second to exit lockout. If control has recycled three times within the same call for heat, it will enter into restricted mode. To reset from restricted mode, refer to Section
VIII, Paragraph I, No. 2 for details. c. CAD cell seeing light. d. CAD assembly defective. e. Control motor relay is stuck closed (see note
below).
2. Burner (control) will light, then shut down after a short time, then restart after one (1) minute.
a. CAD cell is defective.
doogyrevA.ERUDECORPTSETKCEHC otsismelborpedisleufgnitalosiroftset
"42ahtiwdnametsysleufehttcennocsid
evi
fyrailixuanafotuoerif,gnibutfohtgnel
morflio2#mraw,hserf,naelcfoliapnollag
otdetalosisimelborpehtnehtliapyrailixua
ehtnodesugniebsenilleufroleufeht
47
Page 48
b. Air leaking into oil line causing fl ame out. c. Defective nozzle causing fl ame to be erratic. d. Excessive airfl ow or draft causing fl ame to leave
burner head.
e. Excessive back pressure causing fl ame to be
erratic.
3. Control locks out after Trial For Ignition (TFI). a. No oil to burner. b. Shorted electrodes. c. Nozzle clogged. d. Airfl ow too high. e. Ignitor module defective. f. CAD cell defective. g. Oil valve stuck open or closed.
Note: The Safety Monitoring Circuit (SMC) is
designed to provide lockout in the event of a stuck or welded motor relay.
ECITON
51nihtiwdehsilbatsetonsiemalffI
nwonk(noitautcaevlavliofosdnoces
lliwtuokcol)]IFT[noitingIroFlairTsa
deraybdetacidnisituokcoL.rucco
yramirplioehtnodetacolno-dilosDEL
.lortnoc
-skcollortnocehtfiruccolliwpu-hctaL
rofllacagnirudsemit)3(eerhttuo
no-ydaetsybdetacidnisisihT.taeh
.s'DELrebmadnader
SECTION XII: REPAIR PARTS
All MPO Boiler Repair Parts may be obtained through your local Burnham Wholesale distributor. Should you require assistance in locating a Burnham Distributor in your area, or have questions regarding the availability of Burnham products or repair parts, please contact Burnham Customer Service at (717) 481-8400 or Fax (717) 481-8408.
48
Page 49
SERVICE RECORD
DATE SERVICE PERFORMED
49
Page 50
Bare Boiler Assembly
50
Page 51
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51
Page 52
Bare Boiler Assembly
52
Page 53
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53
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Jacket Assembly
54
Page 55
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55
Page 56
56
MPO84 Thru MPO231 Water Boilers - Trim and Controls
Page 57
METI
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57
Page 58
Beckett AFG Burner
58
Page 59
BECKETT OIL BURNER PART NOS. FOR MPO SERIES BOILERS
NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.
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59
Page 60
XIV. LOW WATER CUT-OFF (LWCO) ON HOT WATER BOILERS
GNINRAW
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When
A low water cut-off is required to protect a hot water
boiler when any connected heat distributor (radiation) is installed below the top of the hot water boiler (i.e. baseboard on the same fl oor level as the boiler). In addition, some jurisdictions require the use of a LWCO with every hot water boiler.
Where
The universal location for a LWCO on both gas and oil
hot water boilers is above the boiler, in either the supply or return piping. The minimum safe water level of a water boiler is at the uppermost top of the boiler; that is, it must be full of water to operate safely. Provisions have been made on the MPO supply manifold for a LWCO.
What Kind
Typically, in residential applications, a probe type LWCO is used instead of a fl oat type, due to their relative costs and the simplicity of piping for a probe LWCO.
How to Pipe
Attach the LWCO to the 3/4" NPT connection on the supply manifold. See Figure A2 for more details.
Ideally, manual shutoff valves should be located
above the LWCO and the boiler to allow for servicing. This will allow probe removal for inspection without draining the heating system. Many probe LWCO manufacturers recommend an annual inspection of the probe.
How to Wire
A. AFTERMARKET LWCO
The 120 VAC confi guration can be universally applied to both gas and oil boilers by wiring it in the line voltage service to the boiler (after the service switch, if so equipped).
The presence of water in a properly installed LWCO will cause the normally open contact of the LWCO to close, thus providing continuity of the 120 VAC service to the boiler.
It is recommended to supply power to the probe LWCO with the same line voltage boiler service as shown in Figure A1. See Figure 20 (of this manual) for more details.
Figure A1: Wiring of Aftermarket LWCO
B. MPO LWCO
To simplify installation, the MPO LWCO can be easily installed by removing the LWCO jumper inside the internal junction box and connecting the harness into the boiler Molex plug. Refer to Section II, Paragraph F, Item 2 (of this manual) for more details.
How to Test
Shut off fuel supply. Lower water level until water level is BELOW the LWCO. Generate a boiler demand by turning up thermostat. Boiler should not attempt to operate. Increase the water level by fi lling the system. The boiler should attempt to operate once the water level is above the LWCO.
60
Page 61
Figure A2: LWCO Location
61
Page 62
SERVICE RECORD
DATE SERVICE PERFORMED
62
Page 63
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TABLE 8: BURNER SPECIFICATIONS
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63
Page 64
Limited Warranty
FOR RESIDENTIAL CAST IRON WATER BOILERS
Subject to the terms and conditions set forth below, U.S. Boiler™ Co., Inc. Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1,1991:
ONE YEAR LIMITED WARRANTY
ON RESIDENTIAL GRADE WATER BOILERS
U.S. Boiler Co., Inc. warrants to the original owner that its residential grade water boilers comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation. If any part of a water boiler is found to be defective in material or workmanship during this one year period, U.S. Boiler Co., Inc. will, at its option, repair or replace the defective part.
LIFETIME LIMITED WARRANTY ON HEAT EXCHANGER
U.S. Boiler Co., Inc. warrants to the original owner that the heat exchanger of its residential grade water boilers will remain free from defects in material and workmanship under normal usage for the lifetime of the original owner at the original place of installation. If a claim is made under this warranty during the fi rst ten years from the date of original installation, U.S. Boiler Co., Inc. will, at its option, repair or replace the heat exchanger. If a claim is made under this warranty after the expiration of ten years from the date of original installation, U.S. Boiler Co., Inc. will, at its option and upon payment of the pro-rated service charge set forth below, repair or replace the heat exchanger. The service charge applicable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows:
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sraeY
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NOTE: If the heat exchanger model involved is no longer available due to product obsolescence or redesign, the value used to establish the retail price will be the published price as shown in the Burnham Hydronics Repair Parts Price Sheet where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger.
ADDITIONAL TERMS AND CONDITIONS
1. Applicability: The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada. These warranties are applicable only to water boilers designated as residential grade by U.S. Boiler Co., Inc. and installed in a single or two-family residence and do not apply to steam boilers of any kind or to commercial grade boilers.
2. Components Manufactured by Others: Upon expiration of the one year limited warranty on residential grade water boilers, all boiler components manufactured by others but furnished by U.S. Boiler Co., Inc. (such as oil burner, circulator and controls) will be subject only to the manufacturer’s warranty, if any.
3. Proper Installation: The warranties extended by U.S. Boiler Co., Inc. are conditioned upon the installation of the residential grade water boiler in strict compliance with U.S. Boiler Co., Inc. installation instructions. U. S. Boiler Co., Inc. specifi cally disclaims liability of any kind caused by or relating to improper installation.
4. Proper Use and Maintenance: The warranties extended by U.S. Boiler Co., Inc. conditioned upon the use of the residential grade water boiler for its intended purposes and its maintenance accordance with U. S. Boiler Co., Inc. recommendations and
01-111213141516171
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0454055506560757
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hydronics industry standards. These warranties will be inapplicable if the residential grade water boiler is used or operated over its rated capacity, is subjected to unauthorized modifi cation, or is damaged as a result of being otherwise improperly operated or serviced including, but not limited to, damage from any of the following: operation with insuffi cient water, allowing the boiler to freeze, subjecting the boiler to fl ood conditions, and operation with unapproved water or fuel additives which cause deposits or corrosion.
5. Removal and Installation: These warranties do not cover expenses of removal or reinstallation. The owner is responsible for the cost of removing and reinstalling any defective part and its replacements and all labor and material connected therewith.
6. Exclusive Remedy: U.S. Boiler Co., Inc. obligation for any breach of these warranties is limited to the repair or replacement of its parts in accordance with the terms and conditions of these warranties.
7. Limitation of Damages: Under no circumstances shall U.S. Boiler Co., Inc. be liable for incidental, indirect, special or consequential damages of any kind whatsoever under these warranties, including, but not limited to, injury or damage to persons or property and damages for loss of use, inconvenience or loss of time. U.S. Boiler Co., Inc. liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the residential grade water boiler involved. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
8. Limitation of Warranties: These warranties set forth the entire obligation of U.S. Boiler Co., Inc. with respect to any defect in a residential grade water boiler and U.S. Boiler Co., Inc. shall have no express obligations, responsibilities or liabilities of any kind whatsoever other than those set forth herein. These warranties are given in lieu of all other express warranties.
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO THE HEAT EXCHANGER IN A RESIDENTIAL
dna52
GRADE WATER BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE LIFETIME OF THE ORIGINAL OWNER AT THE ORIGINAL PLACE OF INSTALLATION. SOME STATES DO NO ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU.
PROCEDURE FOR OBTAINING WARRANTY SERVICE
In order to assure prompt warranty service, the owner is requested to complete and mail the attached Warranty Card within ten days after the installation of the boiler, although failure to comply with this request will not void the owner’s rights under these warranties.
Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties, the owner should notify the installer, who will in turn notify the distributor. If this action is not possible or does not produce a prompt response, the owner should write to U.S. Boiler Co., Inc., Burnham Hydronics, at P.O. Box 3079, Lancaster, PA 17604, giving full par ticulars in support of the claim.
The owner is required to make available for inspection by U.S. Boiler Co., Inc. or its representative the parts claimed to be defective and, if requested by U.S. Boiler Co., Inc. to ship these parts prepaid to U.S. Boiler Co., Inc. at the above address for inspection or repair. In addition, the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
03/03
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