U.S. Boiler Company MPO - IQ Service Instructions Manual

INSTALLATION, OPERATING AND

SERVICE INSTRUCTIONS FOR

MPO - IQ™

3-PASS OIL Boiler

9700609

As an ENERGY STAR® Partner, U.S. Boiler Company has determined that the MPO-IQ™ boiler meets the ENERGY STAR®

guidelines for energy efciency established by the United States Environmental Protection Agency (EPA).

For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.

Boiler Model Number

MPO - IQ

Heating Contractor Phone Number

Address

103859-05 - 10/14

Boiler Serial Number Installation Date

Price - $5.00

IMPORTANT INFORMATION - READ CAREFULLY

All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to the following Standards:

USA BOILERS A. Current Edition of American National Standard ANSI/NFPA 31, “Installation of Oil Burning Equipment”, for recommended installation practices. B. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances”, For Venting requirements. C. Current Edition of American Society of Mechanical Engineers ASME CSD-1, “Controls and Safety Devices for Automatically Fired Boilers”, for assembly and operations of controls and safety devices. D. All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or Local Regulations.

CANADIAN BOILERS A. Current Edition of Canadian Standards Association CSA B139, “Installation Code for Oil Burning Equipment", for recommended Installation Practices. B. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or Local Regulations.

The following terms are used throughout this manual to bring attention to the presence of hazards

of various risk levels, or to important information concerning product life.

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

CAUTION

NOTICE

This boiler has a limited warranty, a copy of which is included with this boiler. The warranty for this boiler is valid only if the boiler has been installed, maintained and operated in

accordance with these instructions.

Surface rust on cast iron sections may be attributed to the manufacturing process as well as condensation during storage. Surface rust is normal and does not affect the performance or longevity of a boiler.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other

appliance.

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death. Read and understand all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting-up, operating, maintaining or servicing this boiler. Keep this manual and literature in legible condition and posted near boiler for reference by owner and service technician.

This boiler requires regular maintenance and service to operate safely. Follow the instructions contained

in this manual.

Installation, maintenance, and service must be performed only by an experienced, skilled and knowledgeable installer or service agency.

All heating systems should be designed by competent contractors and only persons knowledgeable in the layout and installation of hydronic heating systems should attempt installation of any boiler.

Installation is not complete unless a pressure relief valve is installed into the 3/4" tapping located on return injector assembly that was installed into boss on top of rear section - See "Packaged Boiler Assy

- Trim & Controls", "Unit-Pak Boiler Assy - Trim & Controls" and "Water Boiler Piping" Sections of this manual for details.

It is the responsibility of the installing contractor to see that all controls are correctly installed and are operating properly when the installation is completed.

This boiler is suitable for installation on combustible ooring. Do not install boiler on carpeting.

Do not tamper with or alter the boiler or controls.

Inspect ueways at least once a year - preferably at the start of the heating season. The inside of the combustion chamber, the vent system and boiler ueways should be cleaned if soot or scale has

accumulated.

When cleaning this boiler, take precaution to avoid damage to burner swing door insulation. If damaged, or if there is evidence of previous damage, burner swing door insulation must be replaced immediately.

Oil Burner and Controls must be checked at least once a year or as may be necessitated.

Do not operate boiler with jumpered or absent controls or safety devices.

Do not operate boiler if any control, switch, component, or device has been subject to water.

Boiler construction materials, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and

other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing

or working nearby the appliance.

This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt

to disconnect any components of this boiler without positively assuring the water is cool and has no

pressure. Always wear protective clothing and equipment when installing, starting up or servicing this

boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool.

WARNING

This boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned

prior to each heating season. A clean and unobstructed chimney ue is necessary to produce the minimum draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. Evidence of loose debris and or condensate induced stains at the base of the chimney ue, connector or smokepipe joints may be signs of condensing ue gases. Flue gas condensate is corrosive, which requires special

consideration and must be addressed immediately. Refer to Section V, "Venting" or Section VI "Direct Venting / Air Intake Piping".

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate

combustion and ventilation air.

This boiler is supplied with controls which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.

wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper,

wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of

re hazards.

All boilers equipped with burner swing door have a potential hazard which, if ignored, can cause severe

property damage, personal injury or loss of life. Before opening swing door, unplug burner power cord from receptacle located in lower right corner of jacket front panel and turn off service switch to boiler

to prevent accidental ring of burner outside the combustion chamber. Be sure to tighten swing door

fasteners completely when service is completed.

TABLE OF CONTENTS

I. Pre-Installation ........................................................................................ 8

II. Packaged Boiler Assy. - Trim & Controls ................................................. 11

III. Unit-Pak Boiler Assy. - Trim & Controls..................................................... 20

IV. Water Boiler Piping .................................................................................. 26

V. Natural Draft Venting ............................................................................... 30

VI. Direct Venting / Air Intake Piping.............................................................. 34

VII. Electrical .................................................................................................. 41

VIII. Oil Piping ................................................................................................. 45

IX. System Start-Up ...................................................................................... 47

X. Operating.................................................................................................. 52

XI. Maintenance & Service Instructions ....................................................... 57

XII. Boiler Cleaning ........................................................................................ 59

XIII. Trouble Shooting ..................................................................................... 61

XIV. Repair Parts ............................................................................................ 69

XV. Burner Specications................................................................................ 83

Appendix A - IQ Oil Control System.......................................................... 85

Appendix B - Figures................................................................................ 89

Appendix C - Tables.................................................................................. 91

Congratulations on your purchase of a new MPO-IQ™ boiler—designed and constructed to provide you with years of reliable service.

• ENERGY STAR™ efciency – friendly on the environment and your wallet.

• Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger.

• *IQ Control™ System– the most advanced and easiest to use controls available.

• System-friendly – built-in protection from condensation and thermal shock.

*IQ Control System Overview

MPO-IQ Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ Control System"

consists of an IQ Oil Boiler Control (Boiler Control) in conjunction with an Oil Primary Control (Oil Primary)and an IQ Option Panel (Option Panel) with optional "plug-in" IQ Option Cards (Option Card). The IQ Control System fully integrates both factory and eld installed components, simplifying installation and troubleshooting. The IQ Control System is designed to efciently operate the entire boiler system to save energy and installation and setup time, while ensuring adequate

supply of heat and domestic hot water.

What's in the crate?

Content Check List

1. MPO-IQ Boiler Assembly on Shipping Skid:

___ MPO-IQ84

___ MPO-IQ115

___ MPO-IQ147

___ MPO-IQ189

___ MPO-IQ231

2. Circulator & Gasket Kit:

___ Taco 007-2 - P/N 8056170

___ Grundfos UP-15 - P/N 102805-01

___ B & G NRF-22 - P/N 8056174

3. Parts Carton:

___ MPO-IQ84 - P/N 103088-01

___ MPO-IQ115 - P/N 103088-02

___ MPO-IQ147/231 - P/N 103088-03

4. Barometric Draft Regulator Carton

___ 5" Dia. - P/N 8116287

___ 6" Dia. - P/N 8116288

___ 7" Dia. - P/N 8116289

5. Instruction Envelope - P/N 103858-01

___ Installation & Operation Manual - P/N 103859-05

___ Boiler Warranty Sheet - P/N 103203-02

Warrantty Registration Tag - P/N 104409-01

Figure 1: MPO-IQ84 Thru MPO-IQ231 Water Boiler

Actual

Shipping

Weight (LB.)

- Sq. Ft.

Surface Area

Heat Transfer

- Gallons

Water Content

Vent

Dia. Inch

Connector

Direct Vent System

Model

Ft.

Height

In. x In.

Rectangle

Requirements

Minimum Chimney

Round

In. Dia.

Boiler

Water

AFUE %

Dimensions See Figure 1

“A” “B” “C”

No.

MPO-IQ84 16-5/8” 24” 5” 7.70 13.29 430

Boiler Model

MPO-IQ115 16-5/8” 24” 5” 7.70 13.29 430

TABLE 1A: DIMENSIONAL DATA (SEE FIGURE 1)

MPO-IQ147 22-5/8” 24” 6” 11.08 20.29 545

MPO-IQ189 28-5/8” 30” 6” 14.46 27.29 658

MPO-IQ231 34-5/8” 36” 7” 17.84 34.29 771

NOTE: 1. Maximum Working Pressure: Water: 30 PSI Shipped From Factory (Standard),

40 PSI Optional, 50 PSI Optional

Ratings

NET AHRI

Burner Capacity

TABLE 1B: RATING DATA

Water MBH

DOE Heating

Capacity MBH

GPH MBH

Boiler

Model No.

MPO-IQ84 0.60 84 74 64 87 6 8 x 8 15 N/A N/A

MPO-IQ115 0.82 115 101 87 87 6 8 x 8 15 N/A N/A

MPO-IQI89 1.35 189 167 145 87 7 8 x 8 15 FDVS-56 5

MPO-IQ147 1.05 147 129 11 2 87 6 8 x 8 15 FDVS-56 5

MPO-IQ231 1.65 231 203 177 87 7 8 x 8 15 FDVS-67 6

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

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 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 oor is not level, or if water may be encountered on 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 (MPO-IQ84 thru 147)

• 30" for ueway cleaning (MPO-IQ189)

• 36" for ueway cleaning (MPO-IQ231)

b. Clearance from Jacket Side Panels -

• 19" for burner swing door, if opened fully with burner mounted, otherwise 1" with b u r n e r removed.

• 12" access clearance to service rear of boiler if other side clearance is less than 12".

• 3" minimum if other side clearance is 12" or larger to access and service rear of boiler.

c. 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 - Chimney Vent (see Figures 2A and 15).

• 24" for rear smokebox cleaning and disconnecting vent pipe from appliance adapter for servicing (if required) - Direct Vent (see Figure 2B).

5. For minimum clearances to combustible materials. See Figures 2A and 2B.

NOTICE

Clearance to venting is for single wall vent pipe. If Type L vent is used, clearance may be reduced to the

minimum required by the vent pipe manufacturer.

Figure 2A: Chimney Vented Boiler - 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-IQ boilers can be installed in rooms with clearances from

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.

I. PRE-INSTALLATION (continued)

C. PROVIDE COMBUSTION AND VENTILATION

AIR. Local and National Codes may apply and should

be referenced.

WARNING

Adequate combustion and ventilation air must

be provided to assure proper combustion and to maintain safe ambient air temperatures.

Do not install boiler where gasoline or other

flammable vapors or liquids, or sources of

hydrocarbons (i.e. bleaches, fabric softeners, etc.) are used or stored.

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(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 unconfined space of a conventionally constructed building, the fresh air

inltration through cracks around windows and doors

normally provides adequate air for combustion and ventilation.

5. For boiler located in a conned space or an unconned

space in a building of unusually tight construction, provide outdoor air.

) = Length(ft) x Width(ft) x Height(ft)

a. Outdoor air for combustion may be provided

with an optional Fresh Air Accessory Kit (ONLY AVAILABLE WITH BECKETT BURNER). Metal cover applications, P/N 611280031. Plastic cover applications, P/N 102119-01. Refer to Fresh Air Accessory Kit instructions for installation and air intake piping details. See Section V for installation details.

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

conned space. Use indoor air if two permanent openings communicate directly with additional

space(s) of sufcient volume such that combined volume of all spaces meet criteria for uncon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.

Figure 2B: Direct Vent Boiler - Minimum Installation Clearances To Combustible Materials (Inches)

I. PRE-INSTALLATION (continued)

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 xed in the open position, or

interlocked with the equipment to open automatically during equipment operation.

D. DIRECT VENT CONFIGURATIONS requires:

1. Beckett NX Burner

2. Direct Vent Conversion Kit

3. Double Wall Flex Oil Vent Pipe (FOVP)

TABLE 2: DIRECT VENT CONFIGURATION COMPONENTS

Boiler

Model No.

MPO-IQ147 103896-03

MPO-IQ189 103897-04

MPO-IQ231 103898-05 102130-03

Beckett NX

Oil Burner

Part No.

Direct Vent

Conversion Kit

Part No.

102130-02

FOVP Carton Part

No.

100211-02 - 5 ft.

100212-02 - 10 ft.

100213-02 - 15 ft.

100214-02 - 20 ft.

100211-03 - 5 ft.

100212-03 - 10 ft.

100213-03 - 15 ft.

100214-03 - 20 ft.

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 miscellaneous parts carton.

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

oor. If necessary, place wooden blocks under front

legs before lowering to provide hand clearance.

Step 7. To lower rear of boiler, tilt boiler 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 oor.

Step 8. If wood block was placed under front legs, lift

pipe handles, remove wooden block and lower front

legs to oor. Remove pipe handles.

CAUTION

Do not drop boiler. Do not bump boiler jacket

against oor.

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 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).

Step 2. Loosen and remove right side latching

hardware (3/8" x 1-3/4" lg. tap bolt and washer).

Step 3. Remove left side latching hardware (3/8" x 1-3/4" lg. tap bolt and washer).

Figure 3: Packaged Boiler Removal from Skid

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

Figure 4A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured

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 Figures 1 and 4B.

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

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

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.

Door to the closed position.

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

Figure 4B: Top View - Burner Swing Door Mounted to Cast Iron Block Assembly (Jacket Removed for Clarity)

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

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 (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 (3/8"-16 x 1-3/4" lg.

tap bolt and at washer) rst, then install left side hinge hardware (3/8"-16 x 1-3/4" lg. tap bolt and at washer) second. Apply additional pressure while hand tightening the hardware as far as possible, then release the pressure.

NOTICE

When securing burner swing door make sure door

is drawn-in equally on both sides.

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 ange bolt 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.

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 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, refer to Figure 4D.

a. By design, cast bars on front section between the

combustion chamber and between the left and right

and 3rd pass ueway should make an impression

side 2 in door insulation to seal the chambers.

b. By design, door insulation on model MPO-IQ231 will

have two (2) by-pass pockets cast into the insulation centered on the bar between the combustion chamber and 3rd pass ueways.

On models MPO-IQ84 thru MPO-IQ189 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

Open miscellaneous parts carton and remove contents.

Identify the components using the illustrations (Figures 5 thru 9) throughout the assembly sequence outlined below as it applies to your installation.

Figure 4C: Top View - Burner Swing Door

Fully Closed but

Not Properly Secured or Sealed

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

Figure 4D: Burner Swing Door Insulation

1. Install return injector piping and relief valve, refer to Figure 5.

Step a. Locate the return pipe ttings and injector. Apply

sealant to the 2” NPT injector threads. Insert injector into 2” NPT upper rear tapping on rear section. Thread 2” NPT x 1-1/2” Reducing Elbow onto 2” NPT injector. Apply thread sealant to the 1-1/2” NPT nipple. Thread 1-1/2” NPT nipple into 1-1/2” NPT end of reducing elbow. Thread 1-1/2” NPT x 1-1/2” NPT x 3/4” NPT

Tee onto 1-1/2” NPT nipple. Tighten pipe ttings until

relief valve orientation is correct for your installation and joints are watertight.

Note: Based on system return piping and access to service

boiler, see Figures 1, 13A and 13B, predetermine if injector piping orientation is to be positioned for vertical, horizontal left or horizontal right side return piping as shown in Figure 5.

Step b. Install relief valve using 3/4" NPT tapping on tee.

Relief valve must be installed in vertical position. If orientation of return injector piping is for:

• 1-1/2" NPT vertical return piping - Install 3/4" NPT x 90° street ell (not furnished) into 3/4” NPT tapping on tee. Install relief valve vertically into street ell. See Figure 5.

Figure 5: Return Injector Piping and Relief Valve

Assembly Details

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

Figure 6: Piping Arrangement for Drain Valve and Indirect Water Heating Return

• 1-1/2" NPT horizontal left or right side return piping - Install relief valve vertically in 3/4" NPT tapping on tee. See Figure 5.

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.

WARNING

Safety valve discharge piping must be piped near

oor to eliminate potential of severe burns. Do not

pipe in any area where freezing could occur. Do not install any shut-off valves, plugs or caps.

2. Install drain valve, see Figure 6.

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 oor drain, when tightening these 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.

3. Connecting eld wiring, refer to Figures 7, 28A thru

28C.

Step a. Locate the black, white and green harness wires

labeled "120V Power Supply" inside internal junction box, see Figure 7. Using wire nuts, connect the 120

volt power supply eld wires to the harness wires.

Step b. Locate the yellow and white wires labeled "System

Circulator" inside internal junction box, see Figure 7.

Using wire nuts, connect the 120 volt eld wires to

the harness wires.

Step c. If applicable, locate the violet and white wires

labeled "DHW Circulator" inside internal junction box, see Figure 7. Using wire nuts, connect the 120

volt eld wires to the harness wires.

Step d. If applicable, locate the brown wire labeled "DHW

Demand" inside internal junction box, see Figure 7.

Using wire nut, connect the 120 volt eld wire to the

harness wire.

Step e. 24V thermostat eld wiring will enter through

5/16" snap bushing located on either the right side or left side jacket panel. Connect the 24V wiring from the thermostat to the "T-T" terminals on the Option Control Panel.

Step f. To connect other external devices, refer to the

instructions included with these devices.

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

WARNING

Wire an additional safety limit such as a low water cut-off or temperature limit device, other than an IQ Control device, in series with the 120V circuit used to power the boiler. Do Not alter the boiler's factory wiring when adding additional limit.

4. Installing Boiler-ECOM harness (only used with Honeywell Oil Primary).

Step a. Locate the black Cat5 harness in the miscella-

neous parts carton.

Step b. Plug RJ45 plug into receptacle on right side

panel, see Figure 1.

Step c. Connect other end of harness into ECOM jack

on Oil Primary.

Step d. Secure harness to right side jacket using the

two wire clamps located in miscellaneous parts carton.

5. Installing stainless steel ueway bafes. Bafe

requirements differ from model to model, see Table 3.

NOTE: Read caution statement before proceeding.

TABLE 3: BAFFLE USAGE

Bafe Usage

Boiler Model

2nd Pass 3rd Pass

MPO-IQ84 None

MPO-IQ115

MPO-IQ147

MPO-IQ231

[2]

P/N 102066-01

[2]

P/N 100042-01

[2]

P/N 100081-01

NoneMPO-IQ189

CAUTION

These bafes will generate higher efciencies and

lower stack temperatures. Under certain conditions, a lower gross stack temperature entering the chimney has the potential to be cooled below the dew point and create condensate on interior surfaces. Flue

gas condensate is corrosive, which requires special

consideration and must be addressed immediately. DO NOT install bafes until you have read Section

V, "Venting" completely.

Figure 7: Internal Junction Box and Wiring Harness Details

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

Figure 8: Bafe Orientation in Flueways

Step a. Install stainless steel bafes provided in

miscellaneous parts carton as follows, refer to Table 3 and Figure 8:

• Model MPO-IQ84 - To install ueway bafe in 3 pass on left side of boiler, hold bafe with word "Left" readable at the top. Slide bafe in ueway until position tab touches ns on left side of 3rd pass ueway. To install ueway bafe in 3rd pass ueway on right side of boiler, hold bafe with word "Right" readable at the top. Slide bafe in ueway until position tab touches ns on right

side of 3rd pass ueway.

• Model MPO-IQ115 - To install ueway bafe in

3rd pass on left side of boiler, hold bafe with word

“Left” readable at the top. Slide bafe in ueway until position tab touches ns on left side of 3rd pass ueway. To install ueway bafe in 3rd pass ueway on right side of boiler, hold bafe with word “Right” readable at the top. Slide bafe in ueway until position tab touches ns on right

side of 3rd pass ueway. To install ueway bafe in 2nd pass on left side of boiler, hold bafe with

word “Left” readable at the top. Slide bafe in ueway until position tab touches ns on left side

of 3rd pass ueway. To install ueway bafe in 2nd

pass ueway on right side of boiler, hold bafe

with word “Right” readable at the top. Slide

bafe in ueway until position tab touches ns

6. 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.

on right side of 3rd pass ueway.

• Models MPO-IQ147, MPO-IQ189 and MPO-

IQ231 - To install ueway bafe in 2nd pass ueway on left side of boiler, hold bafe with word "Left" readable at the top. Slide bafe in ueway until position tab touches ns on right

side of 2nd pass ueway. To install ueway bafe in 2nd pass ueway on right side of boiler, hold

bafe with word "Right" readable at the top. Slide bafe in ueway until position tab touches ns

on left side of 2nd pass ueway.

NOTE: 2nd and 3rd pass ueway bafe are not

interchangeable.

NOTICE

When securing burner swing door make sure door

is drawn-in equally on both sides.

II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd)

Figure 9: Oil Burner Installation (Beckett shown)

7. Install oil burner. (See Figure 9)

Step a. Open burner carton and remove contents.

Step b. Place oil burner gasket on burner and align

holes.

CAUTION

Do not install burner without gasket.

Step c. Remove three (3) 5/16-18 x 3/4 lg. cap screw from

burner swing door used for mounting burner.

Step d. 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 e. Insert oil burner into the opening of burner swing

door. Align and engage keyhole slot in burner ange

over head of protruding cap screw installed in previous

Step. Rotate burner to the right to lock ange behind

head of cap screw.

Step f. Align holes and install two (2) remaining cap

screws. Level burner and fully tighten all three (3) screws.

Step g. Plug burner power cord into power outlet receptacle

located in lower right corner of front panel.

Step h. Check oil nozzle in burner for size, angle and

spray type; inspect electrode settings and head/air plate setting. Refer to Tables 15A thru 15C and 16 and Section IX. Refer to Burner Manufacturer's Manual for detail instructions.

III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS

MPO-IQ Unit-Pak Boiler Assembly Shipment (-LLU)

Content Check List (see Figure 10)

1. ___ Cast Iron Section/Burner Swing Door/Smoke Box Assembly Mounted on Shipping Skid:

____ MPO-IQ84/115 – Part # 103071-02 / 100045-01 / 100021-01

____ MPO-IQ147 – Part # 103071-03 / 100045-01 / 100021-01

____ MPO-IQ189 – Part # 103071-04 / 100045-01 / 100021-01

____ MPO-IQ231 – Part # 1030711-05 / 100045-02 / 100021-01

2. ___ Jacket Carton 4. ____ Control Carton

____ MPO-IQ84/115 – Part # 103069-02 ____ Control Assembly

____ MPO-IQ147 – Part # 103069-03 Part # 103857-01

____ MPO-IQ189 – Part # 103069-04 ____ Jacket Poly Front Cover

____ MPO-IQ231 – Part # 103069-05 Part # 102600-06

3. ___ Part Carton ____ MPO-IQ Logo Plate ____ MPO-IQ84 – Part # 103112-01 Part # 102502-04

____ MPO-IQ115 – Part # 103112-02

____ MPO-IQ147/189 – Part # 103112-03

____ MPO-IQ231 – Part # 103112-05

Figure 10: MPO-IQ Unit-Pak Boiler Shipment Contents (outside container removed)

III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued)

A. REMOVAL OF CAST IRON SECTION/BURNER

SWING DOOR / SMOKE BOX ASSEMBLY FROM SKID.

WARNING

The Cast Iron Section/Burner Swing Door/Smoke Box Assembly has a substantial weight. Insure the travel path to permanent location, as well as mounting surface at boiler permanent location, are structurally sound and rated to handle the boiler weight and water content (refer to Table 1A). Otherwise, a potentially hazardous situation could result in death, serious injury and substantial property damage.

1. Move crated Cast Iron Section/Burner Swing Door/ Smoke Box Assembly and part cartons on the shipping

skid as close to nal permanent location as possible.

2. Remove all fasteners at crate skid. Lift outside container. Examine the skid contents for damage due to shipping and handling.

3. Remove Jacket Carton, Control Carton and Part Carton from skid and set aside.

4. READ AND UNDERSTAND ALL INSTRUCTIONS BEFORE ATTEMPTING BOILER HANDLING AND INSTALLATION.

5. The Cast Iron Section/Burner Swing Door/Smoke Box Assembly is secured to shipping skid with four lag screws. Remove the screws and discard.

6. For manual Cast Iron Section/Burner Swing Door/ Smoke Box Assembly removal prepare one piece of 4” x 4” x 16” lg. (or two pieces of 2” x 4” x 16” lg.) and two pieces of 1” Sch. 40 black pipe to be used as handles.

7. Place wooden block(s) 12” from rear of skid as shown. See Figure 11 “ Boiler Removal from Skid”.

8. Insert 1” Sch. 40 black pipe handles thru leg holes in front and rear section legs. Center rear pipe ends on wooden block(s). See Figure 11.

9. For best leverage, the pipe handles should extend 48” minimum beyond front section face.

10. Using the pipe handles, lift the Cast Iron Section/Burner Swing Door/Smoke Box Assembly until adjustable legs are elevated above the skid deck boards.

11. Remove the skid from underneath the Cast Iron Section/ Burner Swing Door/Smoke Box Assembly.

12. Lower pipe handles until front adjustable legs touch the

oor. Place wood blocks under front legs, if required,

before lowering, to provide hand clearance.

13. To lower rear of the Cast Iron Section/Burner Swing Door/Smoke Box Assembly tilt boiler slightly forward by pushing on smokebox, or, lift pipes protruding thru

rear legs, until wooden block(s) can be removed (see Figure 11). Slowly allow the weight of boiler to tilt

backward until rear legs rest on oor.

14. If wood blocks were placed under front legs, lift pipe

handles; remove the blocks and lower front legs to oor.

Remove pipe handles.

15. Move Cast Iron Section/Burner Swing Door/Smoke Box Assembly to permanent position by sliding or walking.

CAUTION

Do not drop boiler when removing from skid and moving to permanent position.

B. PROCEDURE TO OPEN, CLOSE AND SECURE

BURNER SWING DOOR.

Throughout this manual you will be instructed to open and

close Burner Swing Door for various reasons. There is a proper and improper method of closing and securing the door opened for front jacket panel installation, inspection,

cleaning or eld service. Refer to paragraphs C “Jacket Front

Panel Installation”, and, E “Closing/Securing Burner Swing Door” for details.

C. IMMERSION WELL INSTALLATION

1. Locate immersion well inside Part Carton.

2. Apply thread sealant to ½" NPT male threads.

3. Thread well into ½" NPT boss on top of the front section. Using hex head, tighten well until watertight.

D. JACKET FRONT PANEL INSTALLATION.

In order to install front jacket panel Burner Swing Door and

door mounting bracket need to be removed. As shipped, the door would open to the left side.

1. To open/remove Burner Swing Door (mounted on Cast Iron Section/Burner Swing Door/Smoke Box Assembly) and door mounting bracket for front jacket panel installation:

a. Loosen but not remove door left side latching hardware

(3/8”-16 x 1-3/4” tap bolt).

b. Loosen and remove door right side latching hardware

(3/8”-16 x 1-3/4” tap bolt and 5/16” washer) and set aside.

c. Remove door left side latching hardware (3/8”-16 x

1-3/4” tap bolt and 5/16” washer) and set aside.

d. Lift the door off mounting bracket and set aside.

e. Remove two 5/16”-18 – ¾” hex head cap screws

securing door mounting bracket to front section and set aside.

f. Remove door mounting bracket and set aside.

g. Note/mark cap screw bosses on front section left side;

locate/mark similar two bosses directly opposite on

III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued)

Figure 11: Boiler Removal from Skid

III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued)

front section right side. These four front section bosses are front jacket panel and door mounting bracket attachment points.

2. Open Jacket Carton and locate jacket front panel (has

factory attached 1” berglass insulation). See also “Repair

Parts” Section, “Jacket Assembly” illustration for part

identication.

3. Locate Hardware Bag, remove two 5/16”-18 x ½” Phillips pan head machine screws.

4. Place front jacket panel over front section attachment bosses and align jacket holes with front section boss holes.

5. Firstly, install two 5/16”-18 x ½” Phillips pan head machine screws hand tight to secure front jacket panel right side to casting

6. Secondly, insert 5/16”-18 – ¾” hex head cap screw thru door mounting bracket upper hole and upper hole on left side of front jacket panel simultaneously, and, fasten the bracket and panel to casting hand tight.

7. Thirdly, insert 5/16”-18 – ¾” hex head cap screw thru door mounting bracket lower hole and lower hole on left side of front jacket panel simultaneously, and, fasten the bracket and panel to casting hand tight.

8. Finally, tighten both sets of hardware to secure the bracket and front jacket panel.

9. Inspect 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. Repair or replace, if the rope is damaged, or, there is a gap between the rope ends.

10. Inspect burner swing door insulation for damage and proper type.

By design, for all models, cast bars on front section

between the combustion chamber, and, between the left and right side 2nd and 3rd pass ueways should make an impression in door insulation to seal the chambers.

By design, door insulation on model MPO-IQ231 will

have two by-pass pockets cast into the insulation centered on the bar between the combustion chamber and 3rd pass

ueways. By design, door insulation on models MPO-

IQ84, MPO-IQ115, MPO-IQ147 and MPO-IQ189 will not have any by-pass pockets. If insulation is damaged,

or, improper type regarding the pockets, it must be replaced.

11. Upon inspection completion, lift door and place integral cast hinge pins into door mounting bracket slotted holes. Do not close and secure door at this time, proceed to

installing stainless steel ueway bafes.

E. FLUEWAY BAFFLE INSTALLATION. Refer to Section

II, Paragraph F.

F. CLOSING / SECURING BURNER SWING DOOR.

Refer to Section II, Paragraph D.

G. JACKET REAR PANEL INSTALLATION.

1. Locate jacket rear panel (has factory attached 3” berglass

insulation) inside Jacket Carton. See also “Repair Parts” Section, “Jacket Assembly” illustration for part

identication.

2. Locate and remove from Hardware Bag rear panel mounting hardware – (2 pcs) 5/16”-18 x 3” lg. tap studs, (2 pcs) 5/16”-18 plated acorn nuts, (2 pcs) 5/8” x 2-9/32” round spacers and (2 pcs) 5/16”-18 x ½” Phillips pan head machine screws.

3. Locate rear panel two lower attachment bosses on rear section.

4. Thread both 5/16”-18 x 3” lg. tap studs, with short threaded end, into lower attachment bosses on rear section.

5. Install both 5/8” x 2-9/32” round spacers over tap studs.

6. Place rear jacket panel over rear section, so both tap studs clear thru lower panel holes, rear section cleanout openings clear thru matching panel cut-outs and brass sample port plug clears panel matching hole.

7. Secure panel bottom to studs with acorn nuts hand tight.

8. Align upper panel attachment holes with smokebox upper attachment bosses and install 5/16”-18 x ½” Phillips pan head machine screws hand tight.

9. Securely tighten rear jacket panel mounting hardware.

H. FLUE CLEANOUT COVERS AND SMOKEBOX

COLLAR INSTALLATION.

1. Remove two cast iron Cleanout Covers, cast iron Smokebox Collar and the tube of hi-temperature silicon adhesive sealant from Part Carton. See also “Repair Parts” Section, “Bare Boiler Assembly” illustration for

part identication.

2. Check the rope gasket factory attached to the covers. Repair or replace, if the rope is damaged, or, there is a gap between the rope ends.

3. Locate/remove four 5/16”-18 – 7/8” hex head cap screws from Hardware Bag.

4. Apply a drop of supplied Anti-seize (pouch provided in Part Carton) to each of four (4) 5/16”-18 x 7/8” hex head cap screws for rust protection and to facilitate easy removal for future service.

III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued)

5. Position left Cleanout Cover over rear section cleanout opening, align section boss holes with Cleanout Cover holes, install both 5/16”-18 – 7/8” hex head cap screws hand tight, then, alternately tighten them with open end or socket wrench.

6. Repeat above steps with right Cleanout Cover.

7. Apply the adhesive sealant to the underside of the collar, all around, at the inside corner of the collar outer ring. Insure adhesive bead is complete all around and without gaps.

8. Place the collar over smokebox tongue and align collar integral mounting ear slots with smokebox bosses.

9. Thread-in both 5/16”-18 – 7/8” hex head cap screws hand tight, then, alternately tighten them with open end or socket wrench.

I. INSULATION WRAPPER AND BURNER POWER

OUTLET RECEPTACLE INSTALLATION.

1. Insulation Wrapper is packed in the Jacket Carton.

2. Unfold Insulation Wrapper, position it over section assembly centered left to right and align two wrapper upper holes with 2" NPT pipe tappings in front and rear section top.

3. Tuck Insulation Wrapper bottom ends under section assembly, between front and rear section legs.

4. Locate and remove Burner Power Outlet Receptacle from Part Carton.

5. Insure that the receptacle middle prong opening is facing down. Snap the receptacle into front jacket panel.

J. EXTERNAL ELECTRICAL ENCLOSURE

MOUNTING.

1. Locate and remove Internal J-Box assembly from Part Carton.

2. Remove two #8 x ½” sheet metal screws and three snap bushings from Hardware Bag.

3. Secure the Internal J-Box with sheet metal screws to the top left corner of the Rear Jacket Panel.

4. Install snap bushings into rear of J-Box.

5. Locate and remove J-Box Cover from Part Carton.

6. Secure J-Box Cover to Rear Jacket Panel with two #8 x ½" sheet metal screws from Hardware Bag.

K. TEMPERATURE / PRESSURE GAUGE.

1. Remove the Temperature / Pressure Gauge from Part Carton.

2. Thread the pressure gauge into 1/4” NPT tapping on the front section. Tighten with wrench applied to the square shank of the gauge.

CAUTION

Do not apply pressure to gauge case, as this may result in inaccurate readings.

L. CONTROL PANEL ASSEMBLY AND HARNESS

INSTALLATION.

1. Locate and remove the Control Panel Assembly for the Control Carton.

2. Place Control Panel Assembly on top of Insulation Wrapper.

3. Connect the Red, Black and White Burner wires to Burner Power Outlet Receptacle. Refer to Section VII for wire connections.

4. Feed wires labeled "120V Power Supply", "System Circulator", "DHW Circulator" and "DHW Demand" through the three snap bushings at rear of J-Box.

5. Secure Ground Wire Ring terminal to J-Box using the #8-32 x 3/8" screw from the Hardware Bag.

6. Fully insert sensor into immersion well and secure with sensor clip. See Figure 12.

7. Proceed to Paragraph L for completion of Control Panel Assembly installation.

M. SIDE, TOP JACKET PANEL AND PLASTIC COVER

INSTALLATION.

1. Locate the Right Side Jacket Panel from Jacket Carton. See also "Repair Parts" Section, "Jacket Assembly" illustration for parts identication.

2. Align right side jacket panel mounting holes with front and rear panel holes.

3. Secure with eight #8 x ½" sheet metal screws from Hardware Bag.

4. Install RJ45 jack into Right Side Jacket Panel.

5. Repeat Steps 1 thru 3 for Left Side Jacket Panel.

6. Secure Control Panel Assembly to side Jacket Panels with eight #8 x ½" sheet metal screws from Hardware Bag.

7. Locate the Top Rear Jacket Panel from Jacket Carton. See also "Repair Parts" Section, "Jacket Assembly" illustration

for parts identication.

8. Align top rear jacket panel mounting holes with rear panel holes and secure with three #8 x ½" sheet metal screws from Hardware Bag.

9. Locate the Top Front Jacket Panel from Jacket Carton. See also "Repair Parts" Section, "Jacket Assembly"

illustration for parts identication.

10. Align top front jacket panel mounting holes with side panel holes and secure with two #8 x ½" sheet metal screws from Hardware Bag.

III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued)

11. Locate the Jacket Front Cover from Control Carton. See also "Repair Parts" Section, "Jacket Assembly" illustration

for parts identication.

12. Align jacket front cover mounting holes with side panel holes and secure with four #8 x ½" oval sheet metal screws from Hardware Bag.

N. FIELD ASSEMBLY OF BOILER TRIM AND

BURNERS. Refer to Section II, Paragraph F.

Figure 12: Immersion Well Probe Insertion

IV. WATER BOILER PIPING

NOTICE

Failure to pipe boiler as specied in this manual may result in excessive system noise.

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 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 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.

WARNING

System supply and return piping must be connected to correct boiler piping.

U.S. Boiler Company recommends sizing the

system circulator to supply sufcient ow (GPM)

to allow a 20°F temperature differential in the system. When sizing the system circulator, the most restrictive single zone should be used to determine maximum pressure drop.

CAUTION

Maintain minimum ½ inch clearance from hot water piping to combustible materials.

3. In order to insure long product life, operate boiler at

appropriate ow rate to minimize areas of overheating

a. Design system to ensure that the ow is above the

limit called for in Table 4.

b. Maintain a constant boiler pressure of 12 PSI.

Do not operate boiler below minimum volumetric

ow rates.

TABLE 4: MINIMUM FLOW RATE

Boiler Model No. Flow Rate (Gal / Min)

MPO-IQ84 4.5

MPO-IQ115 6.0

MPO-IQ147 8.0

MPO-IQ189 10.0

MPO-IQ231 12.0

B. CONNECT SYSTEM SUPPLY AND RETURN

PIPING TO BOILER. See Figures 13A and 13B. Also,

consult Residential Hydronic Heating Installation and Design I=B=R Guide.

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. Also, consult Residential Hydronic Heating Installation and Design I=B=R Guide.

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 ow control

valves to prevent gravity circulation of boiler water during the operation of the cooling system.

3. If an indirect water heater is used, priority zoning can be used. Do not use priority zoning for Hydro-Air Systems. Refer to the Indirect Water Heater Installation, Operating, and Service Instructions for additional information.

4. The MPO-IQ is designed to withstand thermal shock from return water temperatures as low as 100°F, but prolonged return temperatures of below 135°F can cause excessive

ue gas condensation and damage the boiler and/or venting

system.

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 ow

for maintenance of higher boiler water temperature.

WARNING

IV. WATER BOILER PIPING (continued)

Figure 13A: Recommended Water Piping for Circulator Zoned Heating Systems

IV. WATER BOILER PIPING (continued)

Figure 13B: Recommended Water Piping for Zone Valve Zoned Heating Systems

+ 64 hidden pages

U.S. Boiler Company MPO - IQ Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual