IN S TAL L AT ION , OP E R AT IN G AN D
S E R V IC E IN S T R U C T ION S F OR
M o d e l M P C ™ M U LT I - P A S S
C O M M E R C I A L C A S T I R O N BO I L E R
3050579
F o r s e rvi c e o r re p a i rs to b o i le r, c a ll yo ur he a ti ng c o ntr a c to r. W he n s e e k i ng i nfo rma ti o n o n
b o i le r, p ro vi d e B o i le r Mo d e l Numb e r a nd S e ri a l Numb e r a s s ho wn o n Ra ti ng L a b e l.
B o i le r Mo d e l Numb e r
B o i le r S e ri a l Numb e r
Ins ta lla ti o n D a te
_ - MP C _ _ - _ _ _ _
He a ti ng C o ntra c to r
Typ e o f F ue l
A d d re s s
P ho ne Numb e r
Commercial Boilers
www.burnhamcommercialcastiron.com
101786-01R5-11/10
Price - $5.00
EQUIPMENT CHECK LIST
NOTE: Only factory packaged and firetested units are eligible to bear the UL listing mark.
This Equipment Check List has been provided so that
the Installer can determine if all parts have been provided
for the boiler ordered. It covers standard equipment for
Knockdown boilers, 4 thru 18 section models. Optional
equipment ordered will be in addition to, or in lieu of,
equipment shown below.
To simplify boiler assembly, instructions refer to carton
designations located in box on Bar Code Labels, see Figure
1a. When instructed, locate and open specified carton.
Some cartons use all contents immediately and others use
Figure 1a: Carton Identification
parts throughout the assembly procedure until depleted.
KNOCKDOWN BOILER - EQUIPMENT CHECK LIST
Qty. Req’d. Per Boiler Size
12 Sect.
13 Sect.
14 Sect.
15 Sect.
16 Sect.
17 Sect.
18 Sect.
1
1
1
1
1
1
1
1
1
1
1
1
1
Center Section - Machined
[Quantity shown shipped on separate
skid(s), Maximum 6 per skid]
MPC-C
100657-01
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16
1
1
9 Sect.
1
8 Sect.
1
7 Sect.
101829-01
6 Sect.
CP-S
5 Sect.
MPC Common Castings & Parts Skid
(Includes Front Section, Rear Section,
Burner Swing Door Assembly,
Rear Flue Collector and
Miscellaneous Common Parts Carton)
Component Description
4 Sect.
11 Sect.
Part
Number
10 Sect.
Carton
Designation
on Bar Code
Label
Castings (Shipped Loose - Field Assembly)
Parts Cartons
Boiler Assembly Cartons
Supply & Return Manifold Carton
Return Water Mixing Tube Cartons
Restricted Clearance
Jacket
Frame
Cartons
BAC4
101831-01
BAC5
101831-02
BAC6
101831-03
BAC7
101831-04
BAC4 Multi
101831-05
BAC5 Multi
101831-06
1
1
1
103818-01
1
102804-04
1
RWMT 5 RC
102804-05
RWMT 6 RC
102804-06
RWMT 7 RC
102804-07
RWMT 8 RC
102804-08
RWMT 9 RC
102804-09
RWMT 10 RC
102804-10
102804-11
102804-12
RWMT 13 RC
102804-13
RWMT 14 RC
102804-14
RWMT 15 RC
102804-15
RWMT 16 RC
102804-16
RWMT 17 RC
102804-17
RWMT 18 RC
102804-18
Jacket Frame (Front/Rear Rails)
JF-1
101834-01
Jacket Frame
(Front/Center/Rear Rails)
JF-2
101834-02
Jacket Frame (Center Rails)
JF-3
101834-03
1
1
1
1
1
1
1
1
S/RM CI
RWMT 11 RC
1
1
RWMT 4 RC
RWMT 12 RC
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
(Continued)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
KNOCKDOWN BOILER - EQUIPMENT CHECK LIST
1
1
18 Sect.
1
17 Sect.
1
16 Sect.
1
15 Sect.
14 Sect.
1
13 Sect.
1
12 Sect.
1
11 Sect.
9 Sect.
1
10 Sect.
8 Sect.
7 Sect.
6 Sect.
5 Sect.
Part
Number
4 Sect.
Component Description
Carton
Designation
on Bar
Code Label
(Continued)
Qty. Req’d. Per Boiler Size
1
1
Parts Cartons (Continued)
Complete Heat Exchanger
Insulation Wrapper
Heat Exchanger
Insulation Bags
Front Heat Exchanger
Insulation Wrapper
Rear Heat Exchanger
Insulation Wrapper
Center Heat Exchanger
Insulation Wrapper
Jacket Common Panels
(Front and Rear)
Jacket Uncommon Panels
(Outer Top Panels, Tie Bars,
Chaseway Channels &
Internal Wiring Harness)
Jacket Panel
Cartons
(4 Cartons
Required per
Boiler)
Jacket Uncommon Top
Panels Cartons
CPHW 4
101835-04
CPHW 5
101835-05
CPHW 6
101835-06
FTHW 1
101849-01
FTHW 2
101849-02
FTHW 3
101849-03
1
1
1
1
RRHW 1
101850-01
RRHW 2
101850-02
RRHW 3
101850-03
CTHW 1
101851-01
CTHW 2
101851-02
JC-1
101836-01
1
JC2- 4
101837-04
1
JC2- 5
101837-05
JC2- 6
101837-06
JC2- 7
101837-07
JC2- 8
101837-08
JC2- 9
101837-09
JC2- 10
101837-10
JC2- 11
101837-11
JC2- 12
101837-12
JC2- 13
101837-13
JC2- 14
101837-14
JC2- 15
101837-15
JC2- 16
101837-16
JC2- 17
101837-17
JC2- 18
101837-18
JC3- 4
101838-04
JC3- 5
101838-05
JC3- 6
101838-06
JC3- 7
101838-07
JC3- 8
101838-08
JC3- 9
101838-09
JC3- 10
101838-10
JC3- 11
101838-11
JC3- 12
101838-12
JC3- 13
101838-13
JC3- 14
101838-14
JC3- 15
101838-15
JC3- 16
101838-16
JC3- 17
101838-17
JC3- 18
101838-18
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
(Continued)
KNOCKDOWN BOILER - EQUIPMENT CHECK LIST
18 Sect.
17 Sect.
16 Sect.
15 Sect.
14 Sect.
13 Sect.
12 Sect.
11 Sect.
10 Sect.
9 Sect.
8 Sect.
7 Sect.
6 Sect.
5 Sect.
Qty. Req’d. Per Boiler Size
Part
Number
4 Sect.
Component Description
Carton
Designation
on Bar
Code Label
(Continued)
Parts Cartons (Continued)
(Continued)
Jacket Panel Cartons
(4 Cartons Required
per Boiler)
Jacket Uncommon Side
Panel Cartons
Second Pass Flueway
Baffle Cartons
(Stainless Steel)
Flueway Baffle Cartons
Third Pass Flueway
Baffle Carton
JC4- 4
101839-04
JC4- 5
101839-05
JC4- 6
101839-06
JC4- 7
101839-07
JC4- 8
101839-08
JC4- 9
101839-09
JC4- 10
101839-10
JC4- 11
101839-11
JC4- 12
101839-12
JC4- 13
101839-13
JC4- 14
101839-14
JC4- 15
101839-15
JC4- 16
101839-16
JC4- 17
101839-17
JC4- 18
101839-18
2FB-18
101840-01
2FB-24
101840-02
2FB-31
101840-03
2FB-38
101840-04
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2FB-45
101840-05
2FB-51
101840-06
1
2FB-58
101840-07
2FB-65
101840-08
2FB- 72
101840-09
2FB- 78
101840-10
3FB
101852-01
1
1
1
WT30-A
101841-01
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
(Cold Rolled Steel)
30 PSI Water Trim
& Control Cartons
Water Trim and
Control Cartons
50 PSI Water Trim
& Control Cartons
101841-02
101841-03
WT30-D
101841-04
WT50-A
101853-01
WT50-B
101853-02
WT50-C
101853-03
WT80-A
101854-01
WT80-B
101854-02
Flue Outlet Damper Carton - 7”
FODC7
102473-01
Flue Outlet Damper Carton - 8”
FODC8
102473-02
Flue Outlet Damper Carton - 10”
FODC10
102473-03
Flue Outlet Damper Carton - 12”
FODC12
102473-04
80 PSI Water Trim
& Control Cartons
WT30-B
WT30-C
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
INSPECT SHIPMENT carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of Boiler to carrier in good condition. Any claims for damage or shortage in
shipment must be filed immediately against the carrier by the consignee. No claims for variances or shortages will be
allowed by Boiler Manufacturer, unless presented within thirty (30) days after receipt of equipment.
IMPORTANT INFORMATION READ and save these instructions for reference
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 National Fuel Gas Code, NFPA 54/ANSI Z223.1.
C. Current Edition of American National Standard ANSI/NFPA 211, “Chimneys, Fireplaces, Vents,
and Solid Fuel Burning Appliances”, for venting requirements.
D. 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.
E. 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. The equipment shall be installed in accordance with the current Installation Code for Gas Burning
Appliances and Equipment, CSA B149, and applicable Provincial Regulations for the class; which
should be carefully followed in all cases.
Authorities having jurisdiction should be consulted before installations are made.
C. All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical
Code and/or Local Regulations.
DANGER
CAUTION
Indicates an imminently hazardous situation
which, if not avoided, will 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.
WARNING
NOTICE
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
Indicates special instructions on installation,
operation, or maintenance which are important
but not related to personal injury hazards.
NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual.
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is complete. The warranty for this boiler is valid only if the boiler has
been installed, maintained and operated in accordance with these instructions.
DANGER
DO NOT store or use gasoline or other flammable 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 appliance before installing, starting-up, operating, maintaining or
servicing this appliance. Keep this manual and literature in legible condition and posted near appliance
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.
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.
Installation is not complete unless a pressure relief valve is installed into the specified tapping on the
supply manifold located on top and at rear of appliance - See Section III, Paragraph R, Item 3 of this
manual for details.
All boiler builds, except boilers bearing the UL Label, are suitable for installation on combustible flooring.
Do not install boiler on carpeting. Do not operate on floors where heat affected material is below.
Do not tamper with or alter the boiler or controls. Retain your contractor or a competent serviceman to
assure that the unit is properly adjusted and maintained.
Clean boiler at least once a year - preferably at the start of the heating season to remove soot and scale.
The inside of the combustion chamber should also be cleaned and inspected at the same time.
Have Burner and Controls checked at least once a year or as may be necessitated. Do not operate
unit with jumpered or absent controls or safety devices. Do not operate unit if any control, switch,
component, or device has been subject to water.
This boiler is designed to operate with lower return water temperatures and avoid thermal shock and
accumulation of condensate if operated per the following criteria:
• Minimum Return Water Temperature = 80°F
• Maximum Delta T Between Boiler Supply and Return = 80°F
• Minimum Supply Water Temperature = 130°F
Continued operation beyond these limitations will result in sustained condensing within the combustion chamber and potentially reduce boiler longevity and may result in premature boiler failure through
thermal shock.
WARNING
Appliance materials of construction, 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 fittings 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.
This appliance must be properly vented and connected to an approved vent system in good condition.
Do not operate boiler with the absence of an approved vent system.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting and air intake systems must be inspected and cleaned before the start of the
heating season and should be inspected periodically throughout the heating season for any obstructions.
Clean and unobstructed venting and air intake systems are necessary to allow noxious fumes that could
cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efficiency.
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 flammable debris, rags, paper,
wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of
fire hazards.
Always keep the oil supply valve shut off if the burner is shut down for an extended period of time.
Probe and float type low water cutoff devices require annual inspection and maintenance. Refer to
instructions in Section VI, Paragraph C for inspection and cleaning instructions.
NOTICE
Model MPC cast iron boilers are designed, built, marked and tested in accordance with the ASME Boiler
and Pressure Vessel Code, Section IV, Heating Boilers. An ASME Data Label is factory applied to each MPC
jacket, which indicates the boiler Maximum Allowable Working Pressure (MAWP). Each cast iron section is
permanently marked with the MAWP listed on the boiler’s ASME Data Label. This value for the MPC is as
follows:
MAWP, Water (USA and Canada) - 80 PSI
It is common and acceptable practice to install these boilers in lower pressure systems, below the boiler
MAWP. Therefore, Burnham offers safety relief valves set at or below the MAWP of the boiler. See Page 12
for available safety relief valve set pressures.
Table of Contents
SECTION I - GENERAL INFORMATION
Dimensional Information.................................................................................................................. 10
Ratings/Data........................................................................................................................................ 12
Locating the Unit ............................................................................................................................... 13
Air Supply/Venting.............................................................................................................................. 14
SECTION II - CAST IRON BLOCK ASSEMBLY INSTRUCTIONS (Knockdown Boiler)
Knockdown Boiler w/ Factory Assembled Section......................................................................... 17
Assembly of Sections, Manual Draw-up ......................................................................................... 18
Assembly of Sections, Hydraulic Draw-up ..................................................................................... 23
Hydrostatic Test . ............................................................................................................................... 24
SECTION III - BOILER ASSEMBLY INSTRUCTIONS (Knockdown Boiler)
Install Common Parts to Block (Hinge Hardware, Flue Collector, Clean-out Covers, Etc.) ....... 25
Install Supply and Return Manifolds ............................................................................................... 27
Install Return Water Mixing Tube...................................................................................................... 27
Install Jacket Support Frame to Block............................................................................................. 30
Install Heat Exchanger Insulation..................................................................................................... 37
Install Internal Wiring Harness Components . ................................................................................ 38
Install Jacket Top Corner Panels ..................................................................................................... 43
Install Jacket Front and Rear Panels . ............................................................................................. 44
Install Jacket Top and Side Panels .................................................................................................. 45
Install Burner Swing Door (BSD) ..................................................................................................... 47
Install 2nd and 3rd Pass Flueway Baffles........................................................................................... 49
Procedure to Close and Secure Burner Swing Door...................................................................... 50
Install Burner Adapter Plate and Mount Burner (Burner Specific)................................................ 50
Connecting Internal Wiring Harness to Burner Controls............................................................... 51
Install Standard Water Trim and Control.......................................................................................... 52
Install Optional Controls:
• Probe LWCO.............................................................................................................................. 54
• High Limit Control w/ Manual Reset....................................................................................... 54
• Low Fire Hold Control.............................................................................................................. 54
• Low / High / Low Control or Modulating Control................................................................... 55
Install Flue Outlet Damper Assembly............................................................................................... 56
Install Optional Burner Swing Door Cover Split Jacket Panels..................................................... 57
SECTION IV - INSTALLATION INSTRUCTIONS
Packaged Boiler - Shipping Information.......................................................................................... 58
Boiler Piping - Heating Applications................................................................................................ 58
Boiler Piping - Domestic Hot Water.................................................................................................. 64
Relief Valve Piping.............................................................................................................................. 64
Electric Wiring.................................................................................................................................... 64
SECTION V - OPERATING INSTRUCTIONS
Filling System..................................................................................................................................... 65
Adjusting Controls............................................................................................................................. 65
Adjusting Burner................................................................................................................................ 65
Test Controls....................................................................................................................................... 66
Initial Cleaning, Water Boilers........................................................................................................... 66
Frequent Water Addition.................................................................................................................... 67
Oxygen Corrosion.............................................................................................................................. 67
Table of Contents (continued)
SECTION VI - SERVICE INSTRUCTIONS
Cleaning Boiler Heating Surfaces..................................................................................................... 68
Maintenance of Low Water Cutoff Devices...................................................................................... 69
Checking Burner & Controls............................................................................................................. 70
Lubrication.......................................................................................................................................... 70
General Maintenance Considerations.............................................................................................. 70
Attention to Boiler While Not in Operation...................................................................................... 70
Recommended Periodic Testing....................................................................................................... 71
SECTION VII - BURNER SPECIFICATIONS
Beckett Burners (Tables XIIIa and XIIIb)........................................................................................... 73
Power Flame Burners (Tables XIVa, XIVb and XIVc)....................................................................... 74
SECTION VIII - REPAIR PARTS
Regional Office Directory.................................................................................................................. 76
Cast Iron Section Assembly.............................................................................................................. 76
Common Bare Boiler Components................................................................................................... 78
Front & Center Section Frame Rail Assembly................................................................................. 82
Rear Section Frame Rail Assembly.................................................................................................. 84
Return Water Mixing Tube Assembly............................................................................................... 86
Heat Exchanger Insulation Wrapper................................................................................................. 88
Internal Wiring Harness Components.............................................................................................. 90
Jacket Panel Assembly...................................................................................................................... 92
2nd and 3rd Pass Flueway Baffles....................................................................................................... 96
Standard Water Trim and Controls................................................................................................... 98
Optional Working Pressure Trim..................................................................................................... 100
Optional Controls............................................................................................................................. 102
APPENDIX A - LIST OF FIGURES................................................................................................................. 104
APPENDIX B - LIST OF TABLES.................................................................................................................. 107
WARRANTY................................................................................................................................. REAR COVER
10
Figure 1b: Dimensional Information
* Wiring harness shown in this location for illustration purposes - typically, wiring harness leads will exit jacket on same side as BSD hinges.
11
14
15
16
17
18
MPC15
MPC16
MPC17
MPC18
128-3/8
121-5/8
114-7/8
108-1/8
101-3/8
94-5/8
87-7/8
54
47-1/4
40-1/2
33-3/4
26-3/8
26-3/8
26-3/8
22-1/2
22-1/2
22-1/2
22-1/2
22-1/2
21
21
21
20-1/2
20-1/2
12-1/4
10-1/4
CF
29-3/8
29-3/8
29-3/8
29-3/8
29-3/8
29-3/8
29-3/8
29
29
29
29
28-1/2
28-1/2
21-3/4
20-3/4
CG
Beckett
39-1/2
39-1/2
39-1/2
39-1/2
34-5/8
34-5/8
34-5/8
34-5/8
34-5/8
34-5/8
34-5/8
29-5/8
29-5/8
29-5/8
29-5/8
C
---
---
---
---
---
---
---
25-3/4
25-3/4
25-3/4
25-3/4
23
23
23
23
JR
Power Flame
* Burner Dimension B (Inches)
* Burner control panel configuration may change this dimension.
13
MPC14
9
10
MPC9
MPC10
MPC13
81
8
MPC8
11
7
MPC7
12
74-1/4
6
MPC6
MPC11
67-1/2
5
MPC5
MPC12
60-3/4
4
MPC4
(Inches)
Boiler
Model
Dim. A
Number
of
Sections
Table I: Dimensional Information
68
75
75
82
88
88
82
68
68
61
55
48
41
35
35
Minimum Flue
Baffle Installation
Clearance Dim. C
(Inches)
12”
12”
12”
12”
12”
12”
10”
10”
10”
10”
8”
8”
8”
7”
7”
Vent (Flue Outlet
Damper)
Connection Size
Dim. D (Inches)
8119
7673
7227
6781
6335
5889
5443
4997
4551
4105
3659
3213
2767
2321
1875
8919
8438
7957
7486
7015
6544
6073
5577
5116
4655
4194
3733
3272
2821
2370
Approx.
Approx. Weight of
Shipping
Sections - LBS.
Weight - LBS.
(Block Assy.)
(KD Boiler)
SECTION I - GENERAL INFORMATION
TABLE II: Ratings/Data
Model MPC™ Boilers
(1)
(2)
(4) Gas (MBH)
Gross Output (MBH)
Net I=B=R Rating
(MBH)
Oil - %
Gas - %
Heating Surface
(Sq. Ft.)
Net Furnace Volume
(Cu. Ft.)
Pressure in Firebox
(Inches Wtr. Column)
Water Content
(Gallons)
3.55
497
500
424
369
89.0
86.3
75.0
7.1
0.10
63
2820
7
MPC5
19.5
5.50
770
773
652
567
88.8
86.1
95.3
9.1
0.19
78
3396
7
MPC6
25.0
7.10
994
995
837
728
88.7
86.0
115.5
11.0
0.28
93
3972
8
MPC7
30.6
8.70
1218 1216
1023
890
88.7
86.0
135.8
12.9
0.34
108
4558
8
MPC8
36.1
10.2
1428 1438
1209
1051
88.6
85.9
156.1
14.8
0.39
123
5144
8
MPC9
41.7
11.8
1652 1660
1395
1213
88.6
85.9
176.4
16.7
0.45
137
5721
10
MPC10
47.2
13.4
1876 1881
1580
1374
88.6
85.9
196.6
18.6
0.50
152
6307
10
MPC11
52.8
15.0
2100 2103
1766
1536
88.5
85.9
216.9
20.6
0.66
167
6893
10
MPC12
58.3
16.6
2324 2325
1951
1697
88.5
85.8
237.2
22.5
0.82
182
7489
12
MPC13
63.8
18.2
2548 2547
2137
1858
88.5
85.8
257.5
24.4
0.98
196
8077
12
MPC14
69.4
19.8
2772 2769
2322
2019
88.5
85.8
277.7
26.3
1.14
211
8673
12
MPC15
74.9
21.5
3010 2991
2508
2181
88.4
85.8
298.0
28.2
1.30
226
9269
12
MPC16
80.5
23.0
3220 3213
2694
2343
88.4
85.8
318.3
30.2
1.30
241
9865
12
MPC17
86.0
24.5
3430 3435
2880
2504
88.4
85.8
338.6
32.1
1.40
256
10470
12
MPC18
91.6
26.0
3640 3657
3065
2665
88.4
85.8
358.8
34.0
1.50
270
11068
12
Vent (Flue Outlet
Damper) Dia.
(Inches)
Oil (MBH)
12.7
w/Water (LBS.)
Oil (GPH)
MPC4
Burner Input
Boiler Weight
Boiler Horsepower
Combustion
Efficiency
Boiler Model
(3)
(1) Suffix “N” indicates natural gas-fired, suffix “P” indicates LP gas-fired, “O” indicates oil-fired, “C” indicates combination natural
gas/oil-fired, “D” indicates combination LP gas/oil-fired.
(2) I=B=R net ratings shown are based on 1.15 piping and pickup factor for water.
Consult manufacturer for installations having unusual piping and pickup requirements, such as intermittent system operation,
extensive piping systems, etc.
(3) The I=B=R burner capacity in GPH is based on oil having a heat value of 140,000 BTU per gallon.
(4) Boiler ratings are based on 13.2% CO2 (oil) and 10.2% CO2 (natural gas) and +.10” water column pressure at boiler flue
outlet.
Ratings shown above apply at altitudes up to 1000 feet on oil and 2000 feet on gas. For altitudes above those indicated, the
ratings should be reduced at the rate of 4% for each 1000 feet above sea level.
Safety Relief Valve Set Pressure: Standard - 50 PSI; Optional - 30 PSI, 80 PSI
12
SECTION I - GENERAL INFORMATION (Continued)
A. INSPECT SHIPMENT carefully for any signs of
From Jacket Left Side Panel:
• Provide clearance per Table I, Dimension
‘B’, for burner swing door (BSD), opened
fully with burner mounted, otherwise 12”
with burner removed.
• 18” access clearance to service rear of boiler
if right side clearance is less than 12”.
• 12” minimum if right side clearance is 18”
or larger to access and service rear of boiler.
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 filed 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 thirty (30)
days after the receipt of goods.
From Jacket Right Side Panel:
• See Table I, Dimension ‘B’ if BSD is
hinged to swing to right side with burner
mounted, otherwise 12” minimum if left
side clearance is 18” or larger to access and
service rear of boiler.
From Jacket Top Panel:
• Provide a minimum clearance from the
boiler jacket of 24”.
B. LOCATE THE UNIT
NOTICE
Recommended clearance for service may be
reduced to minimum clearance to combustible
material. However, increased service and
maintenance difficulty will result.
1. RECOMMENDED SERVICE CLEARANCE
- Locate the unit in the boiler room so as to
provide ease of venting and adequate clearance
for maintenance, serviceability, and installation of
piping. Refer to Figure 1b and Table 1 for boiler
dimensional data.
From Jacket Front Panel:
• Provide 54” service clearance for removal, maintenance, and servicing of burner and
controls.
• Provide service clearance for removal
of baffles to perform annual cleaning of
flueways, refer to Table I, Dimension “C”.
From Jacket Rear Panel:
• Provide a minimum service clearance from
the boiler jacket for access to boiler supply
and return piping, relief valve, drain valve,
flue collector clean-out covers, vent piping
and optional flue damper assembly. See
Table III.
Table III: Recommended Rear Service Clearance
Flue Outlet Size
Combustible or Non-Combustible
Surfaces
7” Dia.
36
8” Dia.
36
10” Dia.
36
12” Dia.
36
2. FOR MINIMUM CLEARANCES to combustible
materials, See Table IV or Table V.
Table IV: Minimum Installation Clearances To
Combustible Materials (Inches) per
ANSI/NFPA 31 (Knockdown/Non-UL
Packaged Boiler)
Boiler
A
Above
B
Front
C
Chimney
Connector
D
Rear
E
Sides
MPC
6
24
18
6
6
Note: See Table III for recommended service clearance
to access rear of boiler.
NOTE 1: Listed clearances comply with American National
Standard ANSI/NFPA 31, Installation of Oil Burning Equipment.
NOTE 2: MPC Series boilers can be installed in rooms with
clearances from combustible material as listed above. Listed
clearances cannot be reduced for alcove or closet installations.
NOTE 3: For reduced clearances to combustible material,
protection must be provided as described in the above ANSI/NFPA
31 Standard.
13
Table V: Minimum Installation Clearances To
Combustible Materials (Inches) per
UL726 (Packaged / Firetested Boiler)
WARNING
All boiler builds, except boilers bearing the
UL Label, are suitable for installation on
combustible floor. Do not install boiler on
carpeting.
Floor construction should have adequate
load bearing characteristics to bear the
weight of the boiler filled with water (see
Table 1). A boiler foundation similar to the
one shown in Figure 2 is recommended if
the boiler room floor is weak or uneven or if
a water condition exists.
A
Boiler Above
MPC
18
B
Front
C
Chimney
Connector
D
Rear
48
18
18
4. PROVIDE AIR SUPPLY AND VENTILATION to
accommodate proper combustion.
E
F
Sides Below
18
WARNING
NC *
Failure to supply adequate air to the boiler will
result in unsafe boiler operation.
* NC - Noncombustible Flooring
Note: See Table III for recommended service clearance
to access rear of boiler.
For commercial and industrial equipment, permanent
facilities for supplying an ample amount of outside air
shall be provided in accordance with the following.
For boiler rooms adjacent to outside walls, and where
combustion air is provided by natural ventilation from
the outside, there shall be a permanent air supply inlet
having a total free area of not less than 1 sq. in. per
4,000 Btu per hr. (35 sq. in. per gal. per hr.) (5.5 cm2
per kw.) of total input rating of the burner or burners
and in no case less than 35 sq. in. (0.425 m2).
For boiler rooms not adjacent to outside walls, the
combustion air shall be supplied in a manner acceptable
to the authority having jurisdiction.
NOTE 1: Listed clearances comply with UL 726, Standard
for Oil-Fired Boiler Assemblies.
NOTE 2: MPC Series 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. PROVIDE ADEQUATE FOUNDATION for the
unit. Refer to Figure 2.
Figure 2: Boiler Foundation
14
a. In the absence of local requirements, the
confined space shall be provided with two
permanent openings, one in or near the top of
the room and one near the bottom. The openings
shall communicate by means of ducts, with the
outdoors or to such spaces (crawl or attic) that
communicate with the outdoors.
i. Where communicating by means of vertical
ducts, each opening shall have a free area of
not less than 1 sq. in. per 4,000 Btuh (35 sq.
in. per gph.) (5.5 cm2 per kw) of total input
rating of all appliances in the enclosure.
ii. If horizontal ducts are used, each opening
shall have a free area of not less than 1 sq.
in. per 2,000 Btuh (70 sq. in. per gph.) (11
cm2 per kw) of total input of all appliances
in the enclosure.
5. CHIMNEY OR VENT (Be sure to read below
WARNINGS.)
The Model MPC™ Series boiler is designed
for forced draft firing and may be used with a
conventional natural draft stack (15’ minimum
height) or a stub vent, sometimes called a diesel
stack (see Figure 3a). See Table I for the
proper vent outlet size. For low silhouette vent
terminations, see Figure 3b. Draft controls are not
normally required, although they may be used on
installations where a natural draft stack is used or on
multiple boiler installations with a common stack. For proper operation, boiler must maintain positive
pressure of 0.1” W.C. at the breech in the cast iron
flue collector during burner high fire operation (see
breeching pressure sensing port in Figure 1b). To
obtain the above, a factory supplied MPC Flue
Outlet Damper Assembly (see Page 56 for details)
must be attached directly to the Rear Flue Collector
Outlet.
If the venting system is designed for positive or
forced draft venting, the boiler, vent connector and
stack will operate under positive pressure. Gas tight
vent systems designed for pressure systems must
Figure 3a: MPC with Rear Outlet Vent
be used to prevent flue by-product leakage. The
vent height is usually limited to prevent negative
draft, typically three (3) feet above the roof line
(see Figure 3a). The damper shall be adjusted to
maintain a positive pressure of 0.1” W.C. at the flue
outlet during burner high fire operation.
If the venting system is designed for negative
pressure (natural draft), the boiler still operates
with positive pressure in the chamber and up to
the fixed damper on the flue collar. However, if
the venting system is larger than what is required,
the stack will provide a surplus draft (or negative
pressure) that may require the use of a barometric
damper to maintain the positive 0.1” W.C. pressure
at the flue outlet. Multiple forced draft boiler stacks
should always be designed as negative to ensure the
products of combustion do not exit a boiler that is
not firing.
NOTICE
When an MPC gas fired boiler is connected to a venting system that is designed so that it will operate
under a negative pressure, the use of Type B, or other manufactured vent systems designed for
negative pressure is acceptable.
When an MPC oil fired or combination gas/oil fired boiler is connected to a venting system that is
designed so that it will operate under a negative pressure, the use of Type L or other manufactured
vent systems designed for negative pressure is acceptable.
Unlined masonry chimneys are not acceptable. Lined masonry chimneys are acceptable with the
appropriate vent connectors using materials described above.
MPC oil or combination gas/oil boilers should be vented using Type L vent, regardless if the vent
pressure is positive or negative.
15
WARNING
Single wall Type C vent material is not approved for MPC boiler venting. When an MPC gas fired boiler
is connected to a venting system that is designed so that it will operate under a negative pressure,
manufactured vent systems, designed and approved for positive pressure application per UL1738,
must be used (for example, Van-Packer Model CS, Protech Model FasNSeal / FasNSeal W2, Heatfab
Saf-T-Vent or equivalent).
When an MPC oil fired or combination gas/oil fired boiler is connected to a venting system that is
designed so that it will operate under a positive pressure, manufactured vent systems, designed and
approved for positive pressure application, must be used (for example, Selkirk Metalbestos Model PS/
IPS, Van-Packer Model ES or equivalent).
Typical Vents that are used on Forced Draft Boilers, on Low Silhouette Buildings
VENT SIZING - Area must be the same as or greater than the boiler breeching (Smoke Outlet). A barometric damper
may be required on installations with a high draft condition.
FAULTY BOILER BURNER OPERATION
1. If improper vent is suspected, remove pipe at breeching and operate boiler. This will determine if excessive
down draft, blocked or restricted flue, etc. is causing the problem.
2. If using type shown in A above, be sure cap is raised sufficiently above main pipe to allow flue gases to vent
unimpeded.
3. A popular type cap is shown in B.
4. The tee is frequently used as shown in C.
5. D and E should not be used due to possible fluctuations in back pressure.
Figure 3b: Vents - Faults and Suggestions
WARNING
Venting Instructions are recommendations only. Consult a venting expert on the design of a specific
vent system for your application. The ASHRAE Venting Guide and The National Fuel Gas Code, NFPA
54 should be considered in all venting systems.
Conventional vent material may not be suitable for the application. Flue gases can leak carbon
monoxide from the joints on these materials and can result in severe personal injury or death.
Installations having long horizontal runs or an excessive amount of tees or elbows will restrict the flow
of combustion gases and can result in condensation, flue gas leakage of carbon monoxide, resulting in
severe personal injury or death.
16
SECTION II - CAST IRON BLOCK ASSEMBLY INSTRUCTIONS
(Knockdown Boilers)
NOTE: Only factory packaged and firetested units are eligible to bear the UL listing mark.
outlined in Section I. Lifting arrangement and weights
A. FACTORY ASSEMBLED SECTIONS - The
are given in Figures 4a and 4b.
assemblage should be set in the proper location as
Number of
Sections
Lifting
Weight
(lbs)
Hooks 1 & 2
Hooks 3 & 4
4
1875
Front
Rear
5
2321
Front
Rear
6
2767
Front
Rear
7
3213
Front
Rear
8
3659
Front
Rear
Lift Locations
9
4105
Section 2
Rear
10
4551
Section 2
Section 9
11
4997
Section 3
Section 10
12
5443
Section 3
Section 10
Figure 4a: Lifting Instructions - Limited to 4 thru 12 Section Block Assembly (No Steel Base)
Optional Steel Shipping Base - 4 thru 12 Section Block
Number of
Sections
Length
A
(Inch)
Width
B
(Inch)
Height
C
(Inch)
Approx.
Center of
Gravity
D (Inch)
Approx.
Shipping
Weight
(Lbs.)
4
51½
48
61½
23¼
2068
5
57½
48
61½
26¼
2546
6
63½
48
61½
29¼
3009
7
69¾
48
61½
32½
3488
8
76
48
61½
35½
3952
9
82
48
61½
38½
4415
10
94¼
48
61½`
44½
4896
11
100½
48
61½
47¾
5360
12
106½
48
61½
50¾
5838
Standard Steel Shipping Base - 13 thru 18 Section Block
Number of
Sections
Length
A
(Inch)
Width
B
(Inch)
Height
C
(Inch)
Approx.
Center of
Gravity
D (Inch)
Approx.
Shipping
Weight
(Lbs.)
13
112½
48
61½
53¾
6301
14
118¾
48½
63½
57
6805
15
125
48½
63½
60
7270
16
131
48½
63½
63
7734
17
137
48½
63½
66
8199
63½
69¼
8663
1. Do not Tilt. Exercise caution when lifting to avoid damage.
18
143¼
48½
2. This boiler can be lifted by fork truck. Do not truck from front.
3. When lifting from rear, forks must extend from beyond center of gravity and second skid cross bar.
4. When lifting from side, forks must extend to opposite skid rail and straddle center of gravity.
5. Cablespreader is to prevent casting damage. Spreader width should equal B (width of skid) +12”.
Adjust cable lengths to lift at approximate center of gravity per chart.
Figure 4b: Lifting Instructions - 4 thru 18 Section Block Assembly w/Steel Base
17
Then proceed to Step C of this section on Page 24,
“HYDROSTATIC TEST”.
B. FIELD ASSEMBLED SECTIONS - If the boiler was
ordered knockdown, to be field assembled, follow the
assembly procedure outlined on the following pages.
1. ASSEMBLY OF SECTIONS (MANUAL DRAWUP)
These sections are designed to be drawn together
one section at a time using the Manual Draw-up Kit
(Burnham P/N 102008-01 or P/N 102008-02) using
ordinary hand tools. Tools required: (1) ¾” Drive Ratchet
(1) 1¼” Socket
(1) 1¼” Combination or Open End Wrench
(1) Can Thread Cutting Oil or Grease
WHEN ASSEMBLING SECTIONS WITHOUT
HYDRAULIC DRAW-UP EQUIPMENT, IT IS RECOMMENDED THAT ONE SECTION BE ASSEMBLED AT A TIME. NEVER ASSEMBLE MORE THAN TWO SECTIONS AT A TIME.
Assembly Procedure (refer to Figure 5 for Exploded
View of Block Assembly and Draw-up Hardware):
Step a. Place the rear section in its approximate
final position, as outlined in Section I. Stand rear
section up and brace in vertical position with a
suitable prop. See Figure 6. Step b. Clean the rope groove around perimeter of
the rear section with a wire brush.
Step c. Open the Boiler Assembly Carton(s),
marked ‘BAC’ and remove contents. Separate
the items by type. There are two (2) different
pre-cut lengths of the red silicone coated
fiberglass rope. The combustion chamber rope is
86” long and the perimeter rope is 164” long.
Step d. Using the multi-purpose spray adhesive
provided, apply the adhesive to the perimeter
rope groove. Follow the directions on the can
for application and tack time. GREAT CARE MUST BE TAKEN TO ENSURE THAT THE ADHESIVE DOES NOT COME IN CONTACT WITH THE MACHINED NIPPLE PORTS.
Step e. While the adhesive is becoming tacky, clean
the nipples ports and nipples thoroughly with a
de-greasing solvent.
Step f. Locate a 164” length of silicone coated
fiberglass rope and 10.3 oz. cartridge of RTV
6500 or RTV 736 Red Silicone Sealant. Starting
at 3 o’clock position, push rope into groove and
continue around perimeter until rope overlaps
the starting point. Rope should be approximately
18
4” longer than required. Use a permanent black
marker to mark the rope approximately 1/8”
beyond point of overlap. Cut off excess with
scissors or utility knife and wooden cutting
block. Apply a generous bead of red sealant to
both ends of cut rope, push ends together and
smooth excess sealant over joint with your finger.
WARNING
Sealant must be properly applied to ALL boiler
joints. Failure to properly seal the boiler joints
will result in combustion gas leaks through the
joint. DO NOT operate boiler with combustion
gas leaks. The sealant should be applied before
each section is placed on the assembly.
Step g. Use the Loctite #592 lubricant supplied to
lubricate the nipples and nipple ports. Apply
the lubricant to the nipples and nipple ports,
then use a brush to disperse it evenly around the
nipples and nipple ports. Use approximately 20
ml of lubricant per flueway [(1) 7” and (1) 3”
nipple and their corresponding nipple ports - (2)
in the rear section and (2) in the next adjoining
section].
Step h. Drive nipples squarely into section using
block of wood and hammer, or preferably, an
aluminum head hammer. Burnham offers a
polyethylene block for setting the nipples (part
no. 8052601). Place block over entire nipple
edge and hit the wood or polyethylene block
with the hammer.
NOTICE
Nipples must be driven in evenly and to the
proper depth to assure tight joints. Most nipple
leaks are caused by tilted or cocked nipples.
DO NOT use steel/iron head hammer to drive
nipples without using a wood or polyethylene
block. Nipple damage may result.
Step i. A special nipple setting gauge is provided
for the nipples. Gauge nipple at 90° angles to
insure that it is driven to the proper depth into
the nipple opening (nipple port). Cut-out in
gauge must rest on nipple, with the legs of the
gauge touching finished face of section, when
nipple is properly driven. See Figure 7.
Step j. Apply a generous bead of RTV 6500 or RTV
736 sealant to the (4) flueway sealing grooves on
rear section. Sealant should start against the rope
gasket, run across the groove in one continuous
bead, and end against rope gasket at the opposite
side. Refer to Figure 5.
19
Figure 5: Manual or Hydraulic Draw-up Section Assembly
Figure 6: Vertical Bracing of Rear Section
Figure 7: Setting of Nipples
Figure 8: Inspection Pad Locations for
Section Draw-up
20
WARNING
This is a forced draft fired boiler and sealant must
be applied where specified for proper and safe
performance. Burnham Commercial has approved
section joint sealants (silastics) manufactured
by Dow-Corning under the product number RTV
736, and Sil-Bond under the product number RTV
6500.
WARNING
Sections must be drawn-up tight immediately
after properly applying sealant for best results.
Although sections may be joined within two
(2) hours of applying sealant, humidity and
temperature affect cure time. If a “thick skin” has
been formed on the sealant bead, remove and reapply sealant.
Step k. Position the next adjoining section to be
assembled, so that the side with the sealing
tongue around the combustion chamber and
perimeter is facing the mating side of the rear
section. Sections must always be assembled
so that the rope groove on one section mates
to the sealing tongue on the next section in the
assembly.
Step l. Clean and lubricate the nipple ports on the
mating (tongue) side of the adjoining section. Place the nipple ports of the adjoining section
onto the nipples previously installed in the rear
section. To facilitate assembly, it is advisable
to enter the upper nipple first in its port. Then
enter the lower nipple in it’s respective port. If
necessary, place a lifting bar (crowbar) under the
center of the section and lift the nipple port onto
the upper nipple. Drive section in place with a
heavy block of wood, striking blows as squarely
as possible over nipple ports.
Step m. From Manual Draw-up Kit, locate and
assemble two (2) sets that include a ¾” x 23”
lg. threaded rod, 6½” dia. pressure plate, ¾”
flat washer and ¾” hex nut as shown in Figure
5. Insert one assembly through each of the 3”
and 4” NPT bosses on rear section until pressure
plate is tight against the boss. Locate and place
the 8¾” dia. pressure plate on the opposite end
of threaded rod in upper nipple port. Place
remaining 6½” dia. pressure plate on rod
protruding through lower nipple port. Install a
¾” washer, ¾” coupling spacer, ¾” washer and
¾” hex nut on each rod. Center upper pressure
plates on nipple port and boss while tightening
nut until tension holds assembly in place. Repeat
for lower assembly. Refer to Figure 5 to verify
proper arrangement.
Step n. DRAW UP SECTION SLOWLY
AND EVENLY. When you start, machined
surfaces between adjoining sections should
be approximately 3/8” to 1/2” apart. The 7”
nipple will pull harder than the 3” nipple. If two (2) people are pulling simultaneously,
stop periodically to verify that gaps between
adjoining sections are equal at both nipple
ports. If not, pull the nipple with the larger
gap until equal before proceeding. Continue
draw-up, paying close attention to the nipple
lubricant as it squeezes when the sections come
in close contact. The lubricant should continue
to squeeze out until the sections are connected
metal to metal at the designated inspection
pads shown in Figure 8. If the sections still
do not appear to be drawn metal to metal,
use the feeler gauge provided to measure any
gaps at the locations identified in Figure 8. (Unless specified otherwise, gaps should be only
measured at these locations). A maximum gap
of .025”.
KEEP NIPPLES ALIGNED WITH NIPPLE
PORTS. If necessary, tap edge of nipples lightly
with a blunt tool or rod to keep nipples from
cocking while sections are being drawn-up. DO NOT DRAW UP SECTION WHEN NIPPLES ARE COCKED. If the torque
required becomes excessive, periodically place a
heavy block of wood over each nipple port and
strike as squarely as possible with several blows
to relieve tension on the draw-up rods.
Step o. Remove Draw-up Rod Assemblies and set
aside.
Step p. Prepare center section on block assembly
to receive next casting, see Figure 5. Clean the
rope grooves around the combustion chamber
and perimeter of the section with a wire brush. Repeat Step ‘d’ through step ‘p’ with the
following exceptions:
• During Step ‘d’ procedure, apply multipurpose spray adhesive to combustion
chamber rope groove as well as perimeter
groove.
• During Step ‘e’ procedure, locate 86”
length of red silicone coated fiberglass rope.
Starting at 9 o’clock position, push rope into
groove and continue around combustion
chamber until rope overlaps starting point. Mark joint, cut-off excess and seal joint per
instructions.
• During Step ‘j’ procedure, apply sealant to
the (6) flueway sealing grooves on the center
section.
BE SURE TO APPLY THE SILICONE
COATED FIBERGLASS ROPE AND
SEALANT to the grooved joints between
21
adjacent sections as the boiler operates with a
positive pressure in the firebox and products of
combustion will escape between sections unless
they are properly sealed. The rope and sealant
should be applied before each section is placed
on the assembly.
All casting legs have two (2) holes. Slide the
lower retention rods through the upper hole in
each leg. Start at the front or rear, which ever is
easiest, per the arrangement shown in Table VI. With the rods in place, install a 5/8” flat washer
and 5/8” hex nut on each rod protruding through
the front legs. On 8 through 18 section block
assemblies, additional rods and couplings nuts
are required to span the distance. On these larger
sizes, thread couplings on front rods to mid point
of coupling (halfway), pull next rod forward to
meet front coupling. Hold front coupling, not
front rod, while threading rear rod into coupling
nut until it contacts front rod at mid point. Repeat this process until both lower rods
protrude through rear section legs. In the
following order, place a 5/8” flat washer, 5/8”
tension spring and 5/8” hex nut on both rods. Hand tighten rear nut only to remove all slack
from the lower rod assemblies. Use a torque
wrench adjusted for 20 ft/lb of torque to tighten
four (4) rear hex nuts. In lieu of a torque
wrench, use a combination wrench to tighten
nuts approximately ¾ turn beyond hand tight, to
set tension.
Excess length of draw-up rods must not extend
beyond front and rear section to ensure proper fit
of jacket, adjust accordingly.
Step s. Release tension on Manual Draw-up
Assemblies and remove.
Now proceed to Step C of this Section on Page
24, Hydrostatic Test.
NOTICE
As assembled length increases, use 3/4” coupling
nuts and additional rods, provided in Kit, to extend
draw-up rod length.
Step q. CONTINUE ASSEMBLING SECTIONS IN THEIR RESPECTIVE ORDER until the
block assembly is complete. Be certain that all
sections are drawn up iron-to-iron at both nipple
ports.
Do not remove the draw-up tool, leave
it under tension until the retention rods are in
place.
Step r. Locate the threaded 5/8” retention rods,
washers, tension springs and nuts supplied
in Boiler Assembly Carton marked ‘BAC’. Assemble both top retention rod assemblies as
shown in Figure 5, Detail B, using the proper
arrangement per Table VI. The tension spring
should always be located at the rear of the boiler. These rod assemblies can be lowered directly
into slotted lugs on each side of the upper nipple
port. Hand tighten the rear nuts only, do not
torque nut at this time. Table VI: Proper Arrangement of Threaded Rods and Coupling Nuts
Block Assembly Size
22
Retention Rod / Coupling Nut Arrangement
Model
Front
Section
Center
Section
Rear
Section
MPC4
1
2
1
24¼” Rod
MPC5
1
3
1
31” Rod
MPC6
1
4
1
37¾” Rod
MPC7
1
5
1
44½” Rod
MPC8
1
6
1
24¼” Rod / Nut / 27” Rod
MPC9
1
7
1
24¼” Rod / Nut / 34” Rod
MPC10
1
8
1
31” Rod / Nut / 34” Rod
MPC11
1
9
1
37¾”” Rod / Nut / 34” Rod
MPC12
1
10
1
44½” Rod / Nut / 34” Rod
MPC13
1
11
1
24¼” Rod / Nut / 27” Rod / Nut / 34” Rod
MPC14
1
12
1
31” Rod / Nut / 27” Rod / Nut / 34” Rod
Front
f
Block Assembly
g
Rear
MPC15
1
13
1
37¾” Rod / Nut / 27” Rod / Nut / 34” Rod
MPC16
1
14
1
44½” Rod / Nut / 27” Rod / Nut / 34” Rod
MPC17
1
15
1
44½” Rod / Nut / 34” Rod / Nut / 34” Rod
MPC18
1
16
1
31” Rod / Nut / 27” Rod / Nut / 27” Rod / Nut / 34” Rod
2. ASSEMBLY OF SECTIONS (HYDRAULIC
DRAW-UP)
• MPC4 through MPC12 Section Assemblies
The entire assemblage may be drawn-up at one time
using the hydraulic draw-up equipment providing
the operation is completed within two (2) hours after
the sealant was applied to the first casting in the
assembly. If time limit is reached, draw-up partial
section assembly before continuing.
the opposite end of threaded rod in upper nipple
port. Place remaining 6½” dia. pressure plate on
rod protruding through lower nipple port.
NOTICE
As assembled length increases, use 3/4” coupling
nuts and additional rods, provided in Kit, to extend
draw-up rod length.
• MPC13 through MPC18 Section Assemblies
The total assemblage should be first drawn-up into
two (2) sub-assemblies. Each sub-assembly may be
drawn-up at one time using the hydraulic draw-up
equipment providing the operation is completed
within two (2) hours after the sealant was applied to
the first casting in the sub-assembly. No more than
12 sections should be drawn up at one time.
“Hydraulic Draw-Up Tool Kit” is available through
Burnham by ordering part number 101904-01.
Step a. Repeat Step ‘a’ through Step ‘l’ under
“Field Assembled Sections (Manual Draw-Up)”.
Step b. Continue driving sections in place (in their
respective order) until all sections are in the
assemblage. Ground surfaces between adjoining
sections should be spaced 3/8” to 1/2” apart. Spacing of more than 1/2” will limit number of
sections that can be drawn up in one unit and
could indicate cocked nipples.
CAUTION
Rods should be approximately centered in
openings so that rods and couplings (when
used) do not drag on pipe thread in end section
tappings.
WARNING
READ THE STATEMENTS BELOW BEFORE
ATTEMPTING TO USE HYDRAULIC EQUIPMENT.
•
Release pressure in ram pumps before
attempting to remove clamps.
•
Do not stand in line with draw-up rods at
either end when hydraulic pressure is being
applied. As a safety measure, ends of drawup rods should be covered while sections are
being drawn in case rods should snap while
under tension.
•
Do not operate ram against draw-up coupling.
WARNING
Sealant must be properly applied to ALL boiler
joints. Failure to properly seal the boiler joints
will result in combustion gas leaks through the
joint. DO NOT operate boiler with combustion
gas leaks. The sealant should be applied before
each section is placed on the assembly.
On long boiler assemblies, it may be necessary
to draw up a partial block if the entire boiler is not
ready to be drawn up tight within two (2) hours
of the first application of the Silastic. If the block
assembly time extends overnight, the partial block
completed must be drawn up tight before leaving
the boiler overnight. If a joint springs apart, it
must be re-drawn tight within two (2) hours of first
application of Silastic to the joint.
Step c. From the Hydraulic Draw-up Kit, locate and
assemble one (1) set of draw-up assemblies that
each include ¾” x 23” lg. threaded rod(s), ¾”
coupling nut(s) (if applicable), the appropriate
pressure plate, washer and ¾” hex nut as shown
in Figure 5. Insert one (1) assembly through
each of the 3” and 4” NPT bosses on rear section
until pressure plate is tight against the boss. Locate and place the 8¾” dia. pressure plate on
Slide ¾” washer, hydraulic ram and second ¾”
washer over each rod assembly. Remove all
slack from assemblies and apply draw-up rod
clamps.
Center upper pressure plates on nipple port and
boss while pumping ram set until tension holds
assembly in place. Repeat for lower assembly. Refer to Figure 5 to verify proper arrangement.
• Do not operate pump after ram has reached
stroke limit.
Step d. Draw-up Sections
Use hydraulic rams to draw up sections by
applying pressure alternately on the draw-up
rods. When rams reach stroke limit, release
pressure in ram pumps and then move clamps to
new position.
Step e. Continue to draw-up until all sections make
contact at the ground joints.
If the sections still do not appear to be drawn
metal to metal, use feeler gauge provided to
measure any gaps at the locations identified in
Figure 8. (Unless specified otherwise, gaps
should be measured at these locations). A
maximum gap of .025” is acceptable.
23
Step f. After all sections have been drawn up,
retention rods must be installed. Do not release
hydraulic pressure until the retention rods are in
place.
Step g. Locate the threaded 5/8” retention rods,
washers, tension springs and nuts supplied in
‘BAC’ Boiler Assembly Carton. Assemble both
top retention rod assemblies as shown in Figure
5, Detail B, using the proper arrangement per
Table VI. The tension spring should always
be located at the rear of the boiler. These rod
assemblies can be lowered directly into slotted
lugs on each side of the upper nipple port. Hand
tighten the rear nuts only, do not torque nut at
this time. All casting legs have two (2) holes. Slide the
lower retention rods through the upper hole in
each leg. Start the front or rear, which ever is
easiest, per the arrangement shown in Table VI. With the rods in place, install a 5/8” flat washer
and 5/8” hex nut on each rod protruding through
the front legs. On 8 through 18 section block
assemblies, additional rods and couplings nuts
are required to span the distance. On these larger
sizes, thread couplings on front rods to mid point
of coupling (halfway), pull next rod forward to
meet front coupling. Hold front coupling, not
front rod, while threading rear rod into coupling
nut until it contacts front rod at mid point. Repeat this process until both lower rods
protrude through rear section legs. In the
following order, place a 5/8” flat washer, 5/8”
tension spring and 5/8” hex nut on both rods. Hand tighten rear nut only to remove all slack
from the lower rod assemblies. Use a torque
wrench adjusted for 20 ft/lb of torque to tighten
four (4) rear hex nuts. In lieu of a torque
wrench, use a combination wrench to tighten
nuts approximately ¾ turn beyond hand tight, to
set tension.
24
Excess length of draw-up rods must not extend
beyond front and rear section to ensure proper fit
of jacket, adjust accordingly.
Step h. Release tension on hydraulic pumps and
rams and remove.
C. HYDROSTATIC TEST - After the boiler sections
have been assembled, it is essential that the boiler
be hydrostatically tested before the jacket frame,
insulation, internal wiring, piping or jacket is installed. This test is an ASME Code Requirement.
1. Block Assembly must be free of air, provide valve in
4” bushing on top supply tapping to purge air during
the filling process. Plug all boiler tappings and fill
entirely with cold water.
CAUTION
DO NOT install gauge until after hydrostatic
testing the boiler. Gauge failure may result.
2. Assembled boilers shall be subjected to a hydrostatic
test of not less than 1½ times the maximum
allowable working pressure, as established by the
relief valve supplied with the boiler. For example, a
boiler with a 50 psi relief valve must be subjected to
a test pressure of 75 psig to 85 psig.
WARNING
Failure to properly hydrotest all boilers at the
correct pressure may result in section assembly
failure in operation.
3. EXAMINE BOILER CAREFULLY, INSIDE AND OUTSIDE, to insure against leaks from
cocked nipples or through concealed breakage
caused in shipping and handling. This precaution
is for your protection and will simplify handling of
necessary replacements and adjustment claims.
4. After making certain that there are no leaks, drain
boiler and remove plugs from boiler trim and other
connections.
25
Figure 9: Installation of Common Parts to Block Assembly
SECTION III - BOILER ASSEMBLY INSTRUCTIONS (Knockdown Boiler)
SECTION III - BOILER ASSEMBLY INSTRUCTIONS (KD Boiler) - Continued
NOTE: Only factory packaged and firetested units are eligible to bear the UL listing mark.
A. INSTALL COMMON PARTS TO BLOCK
ASSEMBLY, Refer to Figure 9.
1. Remove contents from Common Parts Carton
marked ‘CPC’.
2. Locate four (4) C. I. burner swing door (BSD)
hinge/latch castings, two (2) C. I. BSD hinge loop
castings, ten (10) 7/16 split lock washers and ten
(10) 7/16 -14 x 1-1/2 lg. cap screws.
NOTICE
Front section and burner swing door (BSD) are
designed to use universal parts that can be
mounted to make the hinge set work for either
left hand or right hand swing.
For the purpose of these instructions, Burnham
will default to mounting hinge set for left hand
swing (left side).
3. Determine best hinge arrangement for your
installation based on room size, piping arrangement,
burner, fuel lines, utilities and service clearances.
4. For BSD left hand swing (left side hinge) a. Install hinge/latch castings, pin side up, on hinge
pads located on left side of front section. Use
two (2) 7/16” split lock washers and two (2)
7/16 -14 x 1-1/2 lg. cap screws per hinge pin,
see Figures 9 and 10. Secure hardware wrench
tight.
b. Install hinge/latch castings, latch side up, on
hinge pads located on right side of front section
using same hardware for hinge latch as was
used for hinge pin, see Figures 9 and 10. Secure
wrench tight.
Figure 10: Universal Hinge/Latch Casting
c. Locate and position burner swing door (BSD)
vertically against wall or structure to allow
access to both side, front and rear (insulation
side). d. Install hinge loops inside hinge pockets located
on left side of BSD by engaging keyway slot in
loop over pocket key to lock position, see Figure
11. Attach each hinge loop with one (1) 7/16”
split lock washer and one (1) 7/16 -14 x 1-1/2”
lg. cap screw, secure hardware wrench tight.
26
Figure 11: Hinge Loop
5. For BSD right hand swing (right side hinge) a. Repeat 4a thru 4d but install hinge set and
hardware in reverse locations for right hand
swing.
6. Complete Burner Swing Assembly (BSD) - see
Figure 9.
a. Install BSD rope gasket to rear of door.
b. If necessary, clean the rope groove around
perimeter of the BSD with a wire brush.
c. Using the multi-purpose spray adhesive
provided, apply the adhesive to the perimeter
rope groove. Follow the directions on the can
for application and tack time.
d. Locate a 158” length of silicone coated fiberglass
rope from common parts carton. Starting at
3 o’clock position, push rope into groove and
continue around perimeter until rope overlaps the
starting point. Rope should be approximately
4” longer than required. Use a permanent black
marker to mark the rope approximately 1/8”
beyond point of overlap. Cut off excess with
scissors or utility knife and wooden cutting
block.
e. Apply a generous bead of red sealant to both
ends of cut rope, push ends together and smooth
excess sealant over joint with your finger.
WARNING
Sealant must be properly applied to ALL boiler
joints. Failure to properly seal the boiler joints
will result in combustion gas leaks through the
joint. DO NOT operate boiler with combustion
gas leaks.
f. Install observation port sight glass. Locate 2”
x 2-1/2” lg. nipple, sight glass envelope and
2” conduit bushing. Thread 2” nipple into
observation port tapping directly above burner
adapter opening on front of BSD. Open sight
glass envelope and in this order place gasket,
sight glass and gasket into conduit cap. Thread
cap unto 2” nipple, hand tighten only until cap
and glass are snug. Do not over tighten.
g. Do not install BSD on hinges at this time. Door
must be installed after jacket assembly.
7. Mount C. I. flue collector to rear section see Figure 9.
a. Use a wire brush to clean the rope groove on
back surface of rear section.
b. Using the multi-purpose spray adhesive
provided, apply the adhesive to the perimeter
rope groove. Follow the directions on the can
for application and tack time.
c. Locate remaining 158” length of silicone coated
fiberglass rope from common parts carton.
Starting at 3 o’clock position, push rope into
groove and continue around perimeter until
rope overlaps the starting point. Rope should
be approximately 4” longer than required. Use
a permanent black marker to mark the rope
approximately 1/8” beyond point of overlap. Cut off excess with scissors or utility knife and
wooden cutting block.
d. Apply a generous bead of red sealant to both
ends of cut rope, push ends together and smooth
excess sealant over joint with your finger.
e. Locate six (6) 3/8” flat washers and six (6) 3/8
-16 x 1-1/4” lg. cap screws from hardware bag. Thread one (1) washer and cap screw in each
of the bottom tappings approximately four (4)
turns. Lift flue collector and engage bottom slots
over cap screws to position unit on rear section. Install remaining hardware in four (4) upper slots
and hand tighten hardware. Using a wrench,
tighten hardware evenly, use an alternating
pattern from top to bottom.
8. Do not install Flue Collector Clean-out Covers at
this time. Covers must be installed after Jacket
Rear Panels are in place.
9. Install 1/4” NPT brass plug into tapping located at
10 o’clock position on flue outlet collar. Wrench
tighten plug, but do not over tighten. See Figure 9.
10. Apply thread sealant and install 3” NPT pipe plug in
lower tapping on front section. Wrench tighten until
water tight. See Figure 9.
11. Install Supply Manifold and 4” NPT nipple - See
Figure 9.
a. Locate supply and return manifold carton marked
‘S/RM CI’ and remove contents.
b. Apply thread sealing compound to both ends
of the 4” NPT nipple and install one end of the
4” NPT nipple into the non-flow arrowed end
of the CI Supply Manifold and hand tighten the
assembly.
c. Then - Install the threaded end of the 4” NPT
nipple into 4” NPT tapping located on top of rear
section.
d. Wrench - CI Supply Manifold Assembly until
water tight and 1½” NPT tappings (relief valve)
are aligned with front and rear axis as shown in
Figure 12.
Figure 12: Orientation of Supply Manifold
NOTICE
Orientation of supply manifold is critical for
proper alignment of controls and relief valve
piping.
B. Assemble and Install Return Water Mixing Tube
(RWMT RC) and Return Manifold into Block
Assembly.
1. Locate return water mixing tube carton marked
‘RWMT RC’ and remove contents.
2. Modular return water mixing tubes start as a two
(2) tube assembly with end cap and increase with
block size to become a seven (7) tube assembly with
end cap. Assemble each RWMT RC in exact order
shown in Table VII based on boiler size. Also refer
to Figure 13.
3. Per Table VII, starting at the front, install RWMT
End Cap on tube shown in next column to the right. Open ‘RH’ hardware bag and locate 3 oz. tube of
sealant. Apply a continuous bead of silver silicone
sealant to end of tube opposite the flared collar or
ring. The end cap and each tube has a series of
holes for alignment when secured together. Align
the holes, push end cap over tube end with sealant
and secure with four (4) #8 x 1/2 hex head screws. 27
28
Table VII: Modular Return Water Mixing Tube (RWMT RC)
29
Figure 13: Return Water Mixing Tube RC Assembly and Installation
Repeat this process for each joint, securing the
previous assembly to the tube shown in next column
to the right in Table VII, also refer to Figure 13
for details. If space behind the boiler is limited,
on RWMT’s having two or more tubes, it may be
necessary to assemble the end cap to the adjoining
tube and then insert the assembly, capped end first,
into the 4” NPT tapping on the back of the rear
section before joining the remaining tube(s). Allow
approximately 1½” of the tube to protrude from
the tapping, so that the next tube can be secured to
the assembly. Once the next tube is secured, insert
the assembly further into the tapping. Repeat this
procedure as necessary for up to seven (7) tube
RWMT assemblies.
4. Insert the completed RWMT assembly into the 4”
NPT tapping until the end cap reaches the front of
the boiler. The front support clip on the end cap
must rest on the internal shelf inside of the upper 3”
NPT boss on the front section. If necessary, insert
a long screw driver, wooden dowel or a short length
of 1/2 pipe through the 3” NPT tapping and into the
support collar on the end cap to lift and maneuver
the tube into position.
5. Install CI Return Manifold and 4” NPT Nipple - See
Figure 9. a. Apply thread-sealing compound to both ends of
4” NPT nipple and hand tighten nipple into one
end of the CI Return Manifold (return manifold
casting is symmetrical about the ends).
b. Slide the CI Return Manifold Assembly over
RWMT, and install the threaded end of the 4”
NPT nipple into 4” NPT tapping in rear section.
c. Wrench CI Return Manifold Assembly until
watertight and ½” NPT tappings (positioning
plugs) are aligned with vertical axis of rear
section as shown in Figure 14.
6. Thread upper and lower positioning plugs into 1/2”
NPT tappings. If necessary, push forward or pull
back on RWMT assembly and/or rotate until pins on
positioning plugs engage alignment holes in tube,
see Figure 13. Wrench both plugs until water tight.
7. Install RWMT front support plug into 3” NPT
tapping on upper front section boss.
a. Looking through 3” tapped hole, check position
of support collar on RWMT end cap. Collar
should be located approximately in the center of
the tapped hole both vertically and horizontally. b. If necessary, adjust support collar position before
installing front support plug. For horizontal
adjustment, bend support clip up or down per the
amount of visual mis-alignment.
c. Thread front support plug into 3” NPT upper
front section boss, wrench plug water tight.
C. Install Jacket Support Frame to Block Assembly.
1. Locate Jacket Frame Carton(s), marked ‘JF’ and
remove contents, see equipment list on Page 3 for
quantity required.
2. Open “JF-P” Jacket Frame Parts Carton(s), packed
inside Jacket Frame Carton(s), and remove contents.
3. Locate support channel brackets which are shipped
flat and need to be hand formed by bending both
legs down 90°, see Figure 15.
Figure 15: Hand Form Support Channel Bracket
Figure 14: Orientation of Return Manifold
NOTICE
Orientation of return manifold is critical for
proper alignment of return water mixing tube.
30
4. Locate horizontal support channels and FH-1
Hardware Bag(s). Position two (2) support channel
brackets on floor and place horizontal support
channel over brackets. All three (3) holes in both
parts must be in alignment, if they are not, rotate
bracket. Secure brackets to channel using four (4)
#8 x 1/2 hex head sheet metal screws, see Figure 16. Repeat until all horizontal channels and brackets are
assembled.
one (1) 2-5/8” lg. spacer, two (2) washers and one
(1) hex nut on the opposite end of rod. Repeat for
second bracket, refer to assembled end view in
Figure 17b.
7. Mount front/center horizontal channel assembly(lies) to appropriate casting(s) on block
assembly as outlined in Table VIII. Position
threaded rods on channel assemblies over slotted
lugs on casting as shown in Figure 18a. Spread
inside washers until rod drops to bottom of slot
as shown in Figure 18a, Detail ‘A’. Hand tighten
nuts, make sure washers engage casting below
washer retaining lugs, see Detail B. Repeat for all
remaining bracket attachment points.
Figure 16: Secure Brackets to Horizontal Channel
5. Add front/center section mounting hardware to all
but one (1) horizontal support channel assembly. Lay channel assembly on floor with brackets facing
up, see Figure 17a. Install hardware as shown
with two (2) washers and two (2) 1/2” lg. spacers
between bracket legs and one (1) washer and one (1)
hex nut on each end of 3/8” -16 x 3-1/4” lg. rod, see
assembled end view in Figure 17a. Repeat for all
brackets.
6. Add rear section mounting hardware to remaining
horizontal support channel assembly. Lay channel
assembly on floor with brackets facing up, see
Figure 17b. Install hardware as shown with one
(1) 1-3/4” lg. spacer between bracket legs, one (1)
washer and one (1) hex nut on one end of 3/8” -16
x 13-3/8” lg. threaded rod, with one (1) washer,
8. Mount rear horizontal channel assembly to rear
section and adjacent center section as shown in
Figure 18b. Position assembly behind supply
manifold, spread washers and lower threaded rod
into slotted openings on both castings as shown in
Figure 18b, Detail A. Hand tighten nuts, make sure
washers engage casting below washer retaining lugs
as shown in Detail B. Repeat for opposite side.
9. Wrench tighten hex nuts on all channel assemblies
making sure rods are fully seated in slotted
openings.
10. Locate and install lower front/center section
brackets to casting legs. Brackets are universal and
can be used on either side of block assembly. Refer
to Table VIII for appropriate casting leg to be used
for bracket attachment. Brackets mount to rear
surface of leg with offset toward the rear as shown
in Figure 19. Hold bracket at a 45° angle while
engaging upper slot over threaded tie rod, rotate
bracket around rod until lower slot is aligned with
lower hole in casting leg. Insert 5/8 -11 x 2” lg.
bolt with washer through cast hole in leg and slot in
bracket.
Table VIII: Frame/Bracket Mounting Locations
Front
f
Block Assembly
g
Rear
Boiler Size
Frame 1
Frame 2
Frame 3
Frame 4
Frame 5
4 Section
Front Section
Rear Section
-----
-----
-----
5 Section
Front Section
Rear Section
-----
-----
-----
6 Section
Front Section
Rear Section
-----
-----
-----
7 Section
Front Section
Section 4
Rear Section
-----
-----
8 Section
Front Section
Section 5
Rear Section
-----
-----
9 Section
Front Section
Section 5
Rear Section
-----
-----
10 Section
Front Section
Section 6
Rear Section
-----
-----
11 Section
Front Section
Section 6
Rear Section
-----
---------
12 Section
Front Section
Section 5
Section 9
Rear Section
13 Section
Front Section
Section 5
Section 9
Rear Section
-----
14 Section
Front Section
Section 5
Section 10
Rear Section
-----
15 Section
Front Section
Section 6
Section 11
Rear Section
-----
16 Section
Front Section
Section 6
Section 11
Rear Section
-----
17 Section
Front Section
Section 5
Section 9
Section 13
Rear Section
18 Section
Front Section
Section 5
Section 10
Section 14
Rear Section
31
Figure 17a: Front/Center Section Horizontal
Channel Assembly w/Mounting Hardware
Figure 17b: Rear Section Horizontal Channel
Assembly w/Mounting Hardware
32
Figure 18a: Mount Front/Center Section Horizontal Channel to Block Assembly
Figure 18b: Mount Rear Section Horizontal Channel to Block Assembly
33
Figure 19: Attachment of Lower Front/Center Section Bracket to Casting Leg
Figure 20: Attachment of Lower Rear Section Bracket to Casting Leg
34
Hand tighten one (1) 5/8” washer and hex nut on
bolt. Do not wrench tighten at this time. Repeat for
all front/center brackets, both sides.
11. Locate and install rear section brackets to casting
legs. Brackets are universal and can be used on
either side of block assembly. Brackets mount to
front surface of leg with offset toward the rear as
shown in Figure 20. Hold bracket at a 45° angle
while engaging upper slot over threaded tie rod,
rotate bracket around rod until lower slot is aligned
with lower hole in casting leg. Insert 5/8 -11 x 2”
lg. bolt with washer through cast hole in leg and slot
in bracket.
Hand tighten one (1) 5/8” washer and hex nut on
bolt. Do not wrench tighten at this time. Repeat for
bracket on opposite side.
12. Locate and secure vertical side channels (painted
black) to horizontal top channels and lower brackets. Position side channel so pilot hole, on channel face,
is located at the top, see Figure 21. Engage flanges
on vertical side channel over flanges on horizontal
channel and secure with two (2) #8 x 1/2 sheet metal
screws. Engage vertical side channel flanges over
lower bracket, move bracket as necessary to align
holes, secure channel with two (2) #8 x 1/2 sheet
metal screws.
Figure 21: Securing Frame Side Channels to Horizontal Top Channel and Lower Brackets
(Center Section Shown)
35
Figure 22: Lower Tie Bar Installation
Repeat operation until all vertical channels have
been installed. Using an open end wrench and
ratchet with socket, tighten all 5/8” bolts and nuts to
secure frame brackets to casting legs.
13. Locate Jacket Carton(s), marked ‘JC-2’ and remove
contents. Install lower tie bars into slotted ‘I’
openings on lower frame brackets to provide proper
spacing between frame channels, refer to Figure 22. Determine proper location of tie bar by comparing
it’s length to the distance between brackets. Lay
each tie bar on the floor at that location along both
sides of boiler. Step a. Starting at the rear and working to the front,
hold the first tie bar on a slight angle and pass the
end through ’I’ opening in rear bracket as shown
in Figure 22. 36
Step b. Lower the tie bar between brackets as
shown in Figure 22.
Step c. Pull tie bar back and engage opposite end
through ‘I’ opening in front or center section
bracket as shown in Figure 22.
Step d. Engage slotted end of hook over lip of ‘I’
opening and push downward to lock position. If necessary, spread brackets by pushing or
pulling vertical channels until tie bar drops into
locking position, see Detail ‘A’ in Figure 22. For
multiple tie bars, each consecutive bar must be
rotated end for end so the top flanges oppose
each other, for entry into ‘I’ opening, see Detail
‘B’ in Figure 22. Complete process to front
bracket and repeat on opposite side.
Figure 23: Heat Exchanger Insulation - One Piece and Modular Wrappers
D. Locate and Install Heat Exchanger (Block Assembly)
Insulation Wrapper(s), see Figure 23.
1. 4 thru 6 Section Block Assembly - Insulation
wrapper is provided as one-piece that covers block
from front to rear. Drape insulation wrapper over
block assembly with supply manifold hole to the
rear. Starting at top rear, pull insulation under
horizontal channel, open slits and pull insulation
around supply manifold and top brackets on each
side. Pull both sides of insulation back between
vertical channel and rear casting. Open slit at
bottom and position over lower rear bracket. In
the front, starting at the top, pull insulation under
horizontal channel. Open slits and pull insulation
around top brackets. On each side, pull insulation
between vertical channel and front section, position
around door hinge pockets. Open slit at bottom and
position insulation around lower front bracket. Tuck
bottom edges behind lower tie bars.
2. 7 thru 18 Section Block Assembly - Insulation
wrapper is provided in modular pieces that fit
between and join behind each frame rail. If the
insulation width matches the distance between frame
rail brackets, it’s the proper size for that location.
a. Rear Insulation Wrapper - Starting at the rear,
drape rear wrapper over block assembly with
supply manifold hole facing the rear as shown
in Figure 23. Pull insulation under horizontal
channel, open slits and pull insulation around
supply manifold and top brackets on each side. Pull both sides of insulation back between
vertical channel and rear casting. Open slit at
bottom and position over lower rear bracket. Tuck bottom edges behind lower tie bar.
b. Center Insulation Wrapper(s) - 12 thru 18
Section Block Assembly.
Drape center wrapper over block assembly, align
top notches with top frame rail brackets. Push
insulation behind top and side frame rails along
both edges, front and rear. Tuck bottom edges
behind lower tie bars.
c. Front Insulation Wrapper - Drape Wrapper over
Block Assembly. Starting in the front, at the top,
pull insulation under horizontal channel. Open
slits and pull insulation around top brackets. On each side, pull insulation between vertical
channel and front section, position around door
hinge pockets. Open slit at bottom and position
insulation around lower front bracket. Push rear
edges of insulation behind center section frame
rails. Tuck bottom edges behind lower tie bars.
37
E. Installing Internal Wiring Harness for Control/Safety
Circuits - refer to Figures 24a through 24g.
1. See Figure 24a for layout of Internal wiring harness
components.
2. Locate junction boxes shipped in Jacket Frame
Carton marked ‘JF’. As viewed from the rear,
install primary junction box (without extension
piece) to horizontal channel, on the left side of
supply manifold, using two (2) #8 x ½” lg. hex
head sheet metal screws, see Figure 24b. Install
secondary junction box with extension piece to
horizontal channel on right side of supply manifold
using two (2) #8 x ½” lg. sheet metal screws.
Figure 24a: Internal Wiring Harness Components
Figure 24b: Internal Wiring Harness Components - Mounting Junction Boxes
38
3. Locate chaseway channel(s) shipped in Jacket
Carton marked ‘JC-2’, see Figures 24c and 24d. Identify main chaseway channel by it’s unequal
ends. Install the end with 8¼” lg. side flange under
horizontal rail and through openings in junction box
until end protrudes past rear horizontal channel. Secure main chaseway channel to both horizontal
frame rails using #8 x 2½” lg. hex head sheet metal
screws as shown in Figure 24c.
NOTE: Torque screws through rear frame rail until
tight. At this time, only snug screws through
forward rail(s) to allow movement in later assembly
steps when attaching jacket top corner panels.
On 8 thru 18 sections block assemblies, install
chaseway channel extension(s), see Figure 24d. Position channel extension under next horizontal
rail, secure bracket on extension to previously
installed channel with two (2) #8 x ½” lg. hex head
sheet metal screws. Torque these screws until
tight. Secure front of channel extension to next
horizontal rail with two (2) #8 x 2½” lg. sheet metal
screws. Based on block size, repeat until chaseway
extension has been secured to horizontal rail on
front section.
4. Install protective edging to raw edges of chaseway
channel(s) - Locate ‘JH-1’ Hardware Bag, packed
in JC-1 Jacket Carton. From raw stock provided
in Hardware Bag, cut two (2) pieces of protective
edging 1-13/16” lg. and two (2) pieces 4-11/16”
long.
Figure 24c: Internal Wiring Harness Components - Install Main Chaseway Channel
Figure 24d: Internal Wiring Harness Components - Install Chaseway Channel Extension(s)
39
Install 1-13/16” lg. pieces on horizontal raw edges
at both ends of chaseway channel assembly. Install
4-11/16” lg. pieces to vertical chaseway channel
flanges inside primary junction box as shown in
Figure 24e.
5. Locate and install internal control/safety circuit
wiring harness. Start with harness end that has three
(3) connectors, insert connectors through rectangular
opening on front and rear of primary junction box. Pull harness through J-box until second set of three
(3) connectors can be inserted through front opening
in J-box. Center connectors in primary J-box and
secure harness to chaseway using nylon wire tie No.
1, see Figure 24f. Note: If Sage Boiler Control (SBC) is to be used
with boiler, refer to installation section of Sage
Boiler Control Instruction Manual (located in
Sage Boiler Control Parts Carton) at this time.
Review installation section of SBC manual in its
entirety and keep on hand during assembly of
boiler. Installation of SBC sensors and wiring
is much easier when it is done in parallel with
installation of MPC internal wiring harness and
jacket panels.
Pull on harness to remove slack in J-box, secure
harness to end of chaseway channel using wire tie
No. 2 as shown in Figure 24f.
Figure 24e: Internal Wiring Harness Components - Install Protective Edging
Figure 24f: Internal Wiring Harness Components - Install and Secure Harness to Chaseway
40
Insert first set of harness connectors through
opening in rear of secondary junction box. Remove
excess slack between J-boxes until protective sleeve
is centered on raw edge of channel extension, secure
harness to channel using nylon wire tie No. 3, see
Figure 24f.
Use remaining nylon cable ties to secure harness
to chaseway channel at every set of holes, start at
wire tie No. 4 and working forward, removing slack
at each juncture. When securing harness, do not
allow contact with side flanges on channels. Always
position harness between holes.
Table IX: Internal Wiring Harness Adjustment
Boiler
Size
Harness Adjustment
Wire Tie
‘A’
Wire Tie
‘B’
Wire Tie
‘C’
Wire Tie
‘D’
4 Section
CUT
CUT
CUT
CUT
5 Section
CUT
CUT
CUT
---
6 Section
CUT
CUT
---
---
7 Section
CUT
---
---
---
8 Section
No Adjustment Required
9 Section
CUT
CUT
CUT
CUT
6. Determine routing of harness and secure to front
frame channel rails based on burner swing door
(BSD) hinge arrangement determined previously. 10 Section
CUT
CUT
CUT
---
11 Section
CUT
CUT
---
---
12 Section
CUT
---
---
---
Harness can be secured to suit any of the following
arrangements:
13 Section
14 Section
CUT
CUT
CUT
CUT
a. BSD with left hand hinge arrangement - harness
exits left side of jacket front panel en route to
control panel.
b. BSD with left hand hinge arrangement - harness
exits right side of jacket front panel en route to
control panel.
15 Section
CUT
CUT
CUT
---
16 Section
CUT
CUT
---
---
17 Section
CUT
---
---
---
18 Section
No Adjustment Required
No Adjustment Required
Figure 24g: Internal Wiring Harness Components - Secure Harness to Vertical Channel
41
c. BSD with right hand hinge arrangement harness exits right side of jacket front panel en
route to control panel.
d. BSD with right hand hinge arrangement harness exits left side of jacket front panel en
route to control panel.
Locate two (2) cable clamps and secure harness to
vertical rails with two (2) #8 x ½ hex head sheet
metal screws as shown in Figure 24g, clamp must be
facing inward to prevent interference with jacket.
7. Adjust length of internal wiring harness to match
boiler size, see Table IX and Figure 25 for details.
a. 4 thru 8 section boilers are shipped with the
internal harness length suitable for an 8 section
boiler. To modify harness for a 7 section, cut
nylon wire tie A; for a 6 section, cut A & B; for 5
section, cut A, B & C; and for a 4 section, cut A,
B, C & D. Refer to Table IX and Figure 25.
b. 9 thru 13 section boilers are shipped with the
proper harness length suitable for a 13 section
boiler. For boiler sizes 9 thru 12, modify harness
per Table IX, also refer to Figure 25.
c. 14 thru 18 section boilers are shipped with the
proper harness length suitable for an 18 section
boiler. For boiler sizes 14 thru 17, modify
harness per Table IX, also refer to Figure 25.
Figure 25: Internal Wiring Harness - Length Adjustment for Penetration Through Side of Jacket Front Panel
42
F. Locate Jacket Top Corner Panels packed in carton
Step 3. Secure top corner panel #1 to next set of frame
rails with two (2) #8 x ½” lg. SMS, see Figure 26,
Detail A. If necessary, push or pull frame rails to
align holes.
marked ‘JC-2’. Install Jacket Top Corner Panels per
order of assembly shown in Table X, also refer to
illustration in Figure 26.
Step 1. On 4 thru 6 Section Boilers, assemble top
corner panel #1 to 6¾” top corner panel #2 using
two (2) #8 x ½” lg. hex head sheet metal screws,
before installing on frame rails as noted in Step 2.
Step 2. Starting on the left side, at the front, secure
top corner panel #1 to front horizontal and vertical
frame rails with two (2) #8 x ½” lg. hex head sheet
metal screws (SMS).
NOTE: Like the lower tie bars installed previously, these top corner panels maintain the proper distance between frame rails for assembly of remaining jacket panels.
Step 4. On 7 thru 11 Section Boilers, locate top corner
panel #2 per Table X and secure to panel #1 using
two (2) #8 x ½” lg. hex head SMS. Align mounting
holes in panel #2 with holes in frame rails and
secure with two (2) #8 x ½” lg. hex head SMS.
Table X: Jacket Top Corner / Intermediate Panel Arrangement
Boiler Size
4 Section
5 Section
6 Section
7 Section
8 Section
9 Section
10 Section
11 Section
12 Section
13 Section
14 Section
15 Section
16 Section
17 Section
18 Section
Order of Assembly (* See Panel Designation Below)
Side of
Boiler
f
Front
Block Assembly
g
Rear
Left
27” TCP w/J
6¾” TCP w/H
Right
6¾” TCP w/H
27” TCP w/J
Left
33¾” TCP w/J
6¾” TCP w/H
Right
6¾” TCP w/H
33¾” TCP w/J
Left
40½” TCP w/J
6¾” TCP w/H
Right
6¾” TCP w/H
40½” TCP w/J
Left
27” TCP w/J
27” TCP w/H
Right
27” TCP w/H
27” TCP w/J
Left
33¾” TCP w/J
27” TCP w/H
Right
27” TCP w/H
33¾” TCP w/J
Left
33¾” TCP w/J
33¾” TCP w/H
Right
33¾” TCP w/H
33¾” TCP w/J
Left
40½” TCP w/J
33¾” TCP w/H
Right
33¾” TCP w/H
40½” TCP w/J
Left
40½” TCP w/J
40½” TCP w/H
Right
40½” TCP w/H
40½” TCP w/J
Left
34¾” TCP w/J
27” TIP w/J
27” TCP w/H
Right
27” TCP w/H
27” TIP w/J
34¾” TCP w/J
Left
34¾” TCP w/J
27” TIP w/J
33¾” TCP w/H
Right
33¾” TCP w/H
27” TIP w/J
34¾” TCP w/J
Left
34¾” TCP w/J
33-¾” TCP w/J
33¾” TCP w/H
Right
34¾” TCP w/H
33¾” TIP w/J
34¾” TCP w/J
Left
40½” TCP w/J
33¾” TIP w/J
33¾” TCP w/H
Right
33¾” TCP w/H
33¾” TIP w/J
40½” TCP w/J
Left
40½” TCP w/J
33¾” TIP w/J
40½” TCP w/H
Right
40½” TCP w/H
33¾” TIP w/J
40½” TCP w/J
Left
33¾” TCP w/J
27” TIP w/J
27” TIP w/J
33¾” TCP w/H
Right
33¾” TCP w/H
27” TIP w/J
27” TIP w/J
33¾” TCP w/J
Left
33¾” TCP w/J
33¾” TIP w/J
27” TIP w/J
33¾” TCP w/H
Right
33¾” TCP w/H
27” TIP w/J
33¾” TIP w/J
33¾” TCP w/J
* Panel Designations:
TCP w/J = Top Corner Panel w/ Joiner Bracket
TCP w/H = Top Corner Panel w/ Holes
TIP w/J = Top Intermediate Panel w/ Joiner Bracket
43
Step 5. On 12 thru 18 Section Boilers, locate top
intermediate panel(s) #3 per Table X and secure to
panel #1 and each other using two (2) #8 x ½” lg.
hex head SMS per joint. Align mounting holes in
panel(s) #3 with holes in frame rails and secure with
two (2) #8 x ½” lg. hex head SMS per rail.
Locate top corner panel #2 per Table X and secure
to last top intermediate panel #3 installed, using two
(2) #8 x ½” lg. hex head SMS. Secure panel #2 to
rear frame rails using two (2) #8 x ½” lg. hex head
SMS.
Step 6. Repeat same procedure as Steps 1 thru 5 to
install outer top panels to right side frame rails.
Note: Right side of boiler uses same panels as left side with a reverse pattern starting at the rear and working forward.
G. Locate Front Panel Shipped in Jacket Carton marked
‘JC-1’ - Position jacket front panel against front of
boiler assembly and feed internal harness wires through
holes in side of panel as shown in Figure 25.
Figure 26: Install Top Corner / Intermediate Panels
Figure 27: Install Jacket Front Panel
44
Install front panel by tilting on a slight angle to engage
top flange behind bottom flange on jacket top corner
panels installed previously, see Figure 27, Detail A. Rotate bottom of front panel until locking tabs rest
against vertical frame rails. On one side only, flex side
of panel until hooks clear face of vertical rail. Align top
and bottom hooks with slotted holes nearest front edge. Engage both hooks and allow panel to drop down to
lock in place. Repeat for opposite side.
H. Locate Jacket Split Rear Panel shipped in JC-1 Jacket
Carton.
Note: Before installing rear panel, drain valve and indirect water heater return piping (furnished by others) should be installed now due to
accessibility.
Rear panel is shipped loose in two (2) halves, see
Figure 28. As viewed from rear of boiler, install left
split rear panel first. Install panel by tilting on a slight
angle to engage top flange behind bottom flange on
jacket top corner panel, see Figure 29, Detail A. Rotate
bottom of left rear panel until locking tabs rest against
vertical frame rail, flex side of panel until hooks clear
face of vertical rail. Align top and bottom hooks with
rectangular holes nearest rear edge. Engage both
hooks and allow panel to drop down to lock in place,
see Figure 29. Repeat same procedure to install jacket
right split rear panel, making sure that right side panel
overlaps offset flange on left side panel. Secure panel
seam with six (6) #8 x ½” lg. hex head SMS, as shown
in Figure 28.
I. Install two (2) clean-out covers to openings at bottom
of flue collector. Locate four (4) 5/16” flat washers and
four (4) 5/16 -18 x 7/8” lg. cap screws from hardware
bag. Thread one (1) washer and cap screw into left
tapping on each opening. Engage slot on clean-out
cover behind washer. Thread second cap screw with
washer through slot and into tapping on opposite end. Wrench tighten hardware securely. See Figure 9.
J. Locate and Install Blank Sensor J-Box Cover over
opening in Jacket Right Split Rear Panel as shown in
Figure 28. Secure cover with two (2) #8 x ½” lg hex
head SMS.
K. Locate Jacket Top Panel Carton marked ‘JC-3’ and
Figure 28: Jacket Split Rear Panel Detail
remove contents. Starting in the front, install jacket
front top panel first and then add consecutive panel(s)
as outlined in Table XI, working toward the rear of
block assembly.
Figure 29: Install Jacket Split Rear Panel
45
Table XI: Jacket Top Panel Arrangement
Order of Assembly
Boiler
Size
f
Front
Block Assembly
g
Rear
4 Section
22-1/4” Front Top Panel
11-3/8” Rear Top Panel
5 Section
29” Front Top Panel
11-3/8” Rear Top Panel
6 Section
35¾” Front Top Panel
11-3/8” Rear Top Panel
7 Section
22-1/4” Front Top Panel
20-1/4” Intermediate Top Panel
11-3/8” Rear Top Panel
8 Section
22-1/4” Front Top Panel
27” Intermediate Top Panel
11-3/8” Rear Top Panel
9 Section
29” Front Top Panel
27” Intermediate Top Panel
11-3/8” Rear Top Panel
10 Section
29” Front Top Panel
33-3/4” Intermediate Top Panel
11-3/8” Rear Top Panel
11 Section
35-3/4” Front Top Panel
33-3/4” Intermediate Top Panel
11-3/8” Rear Top Panel
12 Section
29” Front Top Panel
27” Intermediate Top Panel
20-1/4” Intermediate Top Panel
11-3/8” Rear Top Panel
13 Section
29” Front Top Panel
27” Intermediate Top Panel
27” Intermediate Top Panel
11-3/8” Rear Top Panel
14 Section
35-3/4” Front Top Panel
27” Intermediate Top Panel
27” Intermediate Top Panel
11-3/8” Rear Top Panel
15 Section
29” Front Top Panel
33-3/4” Intermediate Top Panel
33-3/4” Intermediate Top Panel
11-3/8” Rear Top Panel
16 Section
35-3/4” Front Top Panel
33-3/4” Intermediate Top Panel
33-3/4” Intermediate Top Panel
11-3/8” Rear Top Panel
17 Section
29” Front Top Panel
27” Intermediate
Top Panel
27” Intermediate
Top Panel
27” Intermediate
Top Panel
11-3/8” Rear
Top Panel
18 Section
35-3/4” Front
Top Panel
27” Intermediate
Top Panel
27” Intermediate
Top Panel
27” Intermediate
Top Panel
11-3/8” Rear
Top Panel
Figure 30a: Installing Jacket Top Panels - Viewed From Front
Step 1. Position front panel at approximately 30°
angle, hook front flange under clips on outer top
corner panels as shown in Figure 30a, Detail A, Step
1. Lower rear of panel into position between outer
46
top corner panel and secure front flange to clips
with two (2) #8 x ½” lg. hex head SMS as shown in
Figure 30a. Secure rear flange to outer top corner
panels with two (2) #8 x ½” lg. SMS as shown in
Figure 30b.
Figure 30b: Install Jacket Top Panels
- Viewed From Rear
Figure 30c: Install Jacket Rear
Top Panel Viewed From Rear
Step 2. On 8 thru 18 section boilers, locate
intermediate top panel(s) and install in order of
assembly shown in Table XI. Position panel
between outer top corner panes. Slide forward
to engage locking tabs into slotted openings on
previously installed panel, see Figure 30b. Secure
rear flange with two (2) #8 x ½” lg SMS. Repeat
until intermediate panels reach supply manifold.
Step 3. Position jacket rear top panel between outer
top corner panels behind supply manifold. Slide
forward until locking tabs are engaged into slotted
openings on previously installed panel. Secure
panel to rear clips on outer corner panels with two
(2) #8 x ½” lg. SMS. Refer to Figure 30c.
L. Install Burner Swing Door (BSD) on Block Assembly
hinges, see Figure 31. Move BSD to front of boiler. Position door on the Floor, standing up, perpendicular
to front of boiler (full open position).
Figure 31: Install Burner Swing Door
47
Important Product Safety Information
Refractory Ceramic Fiber Product
Warning:
The Repair Parts list designates parts that contain refractory ceramic fibers
(RCF). RCF has been classified as a possible human carcinogen. When
exposed to temperatures about 1805°F, such as during direct flame contact,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.
AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts 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 fitting 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 airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.
First Aid Procedures:
•
•
•
•
48
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 difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.
Lift door high enough to move hinge pockets through
opening in jacket front panel. Engage hinge loop
attached to door over hinge pin attached to block
assembly. Lower door to rest weight on hinge pin
brackets.
2. On 4 thru 18 Section Boilers - Install four (4) second
pass baffles into second pass flueways until handle
is flush with face of casting as shown in Figure 33,
Detail A.
M. Locate Flueway Baffle Carton(s) marked ‘2FB’ and
‘3FB’ and remove contents. Check Equipment Check
List for proper baffle length and usage per boiler size.
1. On 4 thru 11 Section Boilers - Install four (4) third
pass baffles into third pass flueways until handle is
flush with face of casting as shown in Figure 32,
Detail A.
Figure 32: Install 3rd Pass Flueway Baffles (4 thru 11 Section Boilers Only)
Figure 33: Install 2nd Pass Flueway Baffles
49
N. Close Burner Swing Door and secure using (4) 5/8”
flat washers, (4) 9/16” lock washers and (4) 9/16 - 12
x 2” lg. cap screws as shown in Figure 34. There are
(4) points of internal contact around perimeter of BSD
and Front Section. These stop the door travel when
tightening hardware to prevent excess compression
of rope gasket. Therefore, continued tightening of
hardware will only bend the hinge pockets. Use a hand
wrench to tighten the hardware. Use an alternating
tightening method from right side to left side cap
screws to secure door until sealed without applying
excessive torque. Never tighten hardware on either side
100% without using the alternating tightening method. Failure to follow the prescribed procedure could cause
thread damage, a crack in the casting or a leak in the
door seal.
O. Mount Burner Adapter Plate to Burner Swing Door,
refer to Figures 35 and 36.
Also, refer to Burner Installation Manual for mounting
instructions specific to each burner (provided with
burner).
Figure 34: Secure Burner Swing Door for Tight Perimeter Seal
Figure 35: Install Burner Adapter Plate and Burner to Burner Swing Door
50
Figure 36: Burner Adapter Plate Options
Beckett (‘CF’ Series) Burner Adapter Plate
Power Flame (‘C’ Series) Burner Adapter Plate
Boiler Model
Part No.
I.D.
No.
‘A’
‘B’
10-1/4
MPC4 thru MPC7
602263001
00
6-3/4
10
602263011
01
8-1/4
10
602263021
02
10-1/4
11
Boiler Model
Part No.
I.D.
No.
‘A’
‘B’
MPC4 thru MPC7
602263401
40
7-1/2
MPC8 thru MPC14
602263411
41
9
12
MPC8 thru MPC15
MPC15 thru MPC18
602263421
42
10-3/8
14-1/8
MPC16 thru MPC18
Beckett (‘CG’ Series) Burner Adapter Plate
Power Flame (‘JR’ Series) Burner Adapter Plate
Boiler Model
Part No.
I.D.
‘A’
‘B’
No.
MPC4 thru MPC7
602263451
45
6-3/8
10-1/4
MPC8 thru MPC11
602263461
46
8-3/8
11-11/16
Boiler Model
Part No.
I.D.
No.
‘A’
‘B’
MPC4 and MPC5
602263031
03
5
10
MPC6 and MPC7
602263041
04
6
10
MPC8 thru MPC11
602263071
07
7-1/4
10
MPC12 thru MPC18
602263081
08
8-1/8
11
1. In most cases the burner adapter plate carton for the
specified burner will be provided by Burnham.
2. If adapter is provided by Burnham, open carton
and remove contents. Apply four (4) small dabs
of silastic on rear surface of adapter plate to
temporarily hold gasket in place. Hold adapter plate
in position against burner swing door, align holes
and secure with four (4) 3/8” lock washers and
3/8” - 16 x 7/8” lg. cap screws.
3. If adapter is furnished with burner, follow
manufacturer’s instructions using gasket material
and hardware provided with burner.
4. USE A HOLE SAW OR KNIFE TO CUT BURNER
SWING DOOR INSULATION TO MATCH
HOLE SIZE ON BURNER ADAPTER PLATE. After cutting, remove any and all loose pieces of
insulation which may become lodged or interfere
with the head of the burner air tube after insertion.
5. Secure burner to adapter plate with four (4) ½” lock
washers and four (4) ½” - 13 hex nuts provided.
CAUTION
Failure to properly fill all gaps between the
insulation and burner blast tube may result in
damage to the burner.
6. Confirm that hole in insulation fits snugly around
burner blast tube. If hole is oversized, open burner
swing door (with burner attached) to access burner
blast tube. Use additional fiberglass rope gasket
provided with burner to fill in any space between
insulation and blast tube. If additional rope gasket
is not provided with the burner, use 3/8” fiberglass
rope rated for 2300°F (provided by others).
When finished, close burner swing door and secure
hardware.
P. Connect Internal Control / Safety Circuit Wiring
Harness to Burner Controls, see Figures 25 and 37. Also, refer to Burner Installation Manual and wiring
diagrams provided with burner.
51
Figure 37: Install Jacket Front Panel Harness Cover Plates and Logo Plate
9. Connect other end of flexible conduit to burner
control panel or junction box. Connect control/
safety circuit wires to appropriate terminals per
wiring diagram provided with burner.
1. Harness is split into two (2) 7 wire bundles that exit
side of front panel as shown in Figure 25.
2. Each seven (7) wire harness bundle must be encased
in flexible conduit from cover plate to burner control
panel or junction box.
Q. Install Logo Plate on Jacket Front Panel if Optional
3. Locate front panel cover plates in JC-1 carton.
4. Determine routing, length and type of ‘BX’
connectors to be used on flexible conduit.
5. Mount ‘BX’ connector and flexible conduit to
one (1) front panel cover plate. Pull wire bundles
through conduit.
6. Secure cover plate to side of jacket front panel using
(2) #8 x 1/2” lg. hex head SMS.
7. Locate and install one (1) plastic hole plug
(provided) into unused 7/8” dia. hole in cover plate.
R. Locate Water Trim and Control Carton marked ‘WT’
8. Install remaining cover on opposite side of front
panel. Secure with #8 x 1/2” lg. hex head SMS,
push (3) plastic hole plugs into 7/8” dia. holes.
Figure 38: Purpose of Tappings in Supply Manifold
52
Jacket Split Burner Swing Door Cover Panels are not to
be used.
Locate Logo Plate shipped in Instruction Envelope. Peel paper off adhesive strips and install by inserting
positioning tabs on rear of Logo Plate into slotted
openings located at top of front panel shown in Figure
37. If optional BSD cover panels are used, Logo Plate will
be installed on the cover as instructed in later steps.
and remove contents. Check Equipment Check List for
proper working pressure/relief valve. Install standard
trim and controls as follows:
1. See Figure 38 for purpose of tappings on supply
manifold.
* Location
Size of
Tapping
Purpose of Tapping
A
4” Flange
Supply
B
1½”
Relief Valve
C
1½”
Auxiliary Tapping (Plug)
D
¾”
Operating Temperature
Limit Control
E
¾”
Probe L.W.C.O.
F
¾”
High Temperature Limit Control /
Manual Reset
G
½”
Temperature / Pressure Gauge
H
¾”
Low / High / Low
or Modulating Control
J
½
Low Fire Hold Control
* Supply Manifold must be installed with 1½” coupling ‘B’
or ‘C’ aligned with front of boiler when water tight.
Note: Supply manifold must be installed with 1½”
couplings aligned with front and rear axis of boiler.
2. Apply thread sealant and install temperature/
pressure gauge into tapping ‘G’, see Figures 38 and
39. Wrench until water tight. Tighten gauge using
hex on stem, do not tighten or apply pressure to
case.
3. Apply thread sealant and install relief valve and
pipe fittings in Tapping ‘B’, see Figure 38. Fittings
should be arranged as shown in Figure 39. By code,
relief valve must be installed vertically. Based on
vent pipe arrangement and access, relief valve can
be installed with discharge facing a left or right.
4. Apply thread sealant to 3/4” immersion well
and install in tapping ‘D’ as shown in Figure 38. Wrench well until water tight.
5. Locate L4006A Operating Control and remove
knockout on casing closest to mounting hole. Connect end of harness with forked terminals to
casing knockout. Connect wires to terminal on limit
control, wires are interchangeable. Refer to Figure
39.
6. Connect opposite end of L4006A Operating Control
Harness to right side junction box cover ‘A’, hole
location #1 as shown in Figure 40.
7. Locate mating connectors labeled “operating
control” inside right junction box. Join mating
connectors which are polarized
and lock together. Lightly tug on
connectors to make sure they are
secure.
8. If no other controls are being
installed at this time, secure Cover
‘A’ and Cover ‘B’ to jacket rear top
panel with two (2) #8 x 1/2” lg. hex
head SMS per cover. Install 7/8”
knockout plugs (provided) to all
unused holes, refer to Figure 40.
Figure 39: Install Standard Trim and
Operating Control
Figure 40: Control Connections to
Internal Wiring Harness
53
S. Installing Optional Controls (if applicable):
1. Install M&M 750P-MT-120 Probe Low Water Cut
Off (LWCO)
a. Apply thread sealant to ¾” probe and install in
Tapping ‘E’, see Figure 38. Wrench hex until
water tight.
b. Remove 2nd knockout from bottom of M&M
750P LWCO control case. Connect end
of harness with forked terminals to casing
knockout, see Figure 41. Connect wires to
terminal block as follows:
Terminal 1 - Black Wire w/ Red Tracer
Terminal 2 - Pink Wire
Terminal 3 - Red Wire w/ Black Tracer
Terminal 4 - Brown Wire
Terminal 5 - Violet Wire
c. Mount LWCO Control on probe and tighten
screws.
d. Connect ring terminal on black probe wire from circuit board to terminal on probe and tighten
wing nut.
e. Connect opposite end of M&M 750P LWCO
control harness to left side junction box cover
‘B’, hole location #7 as shown in Figure 40.
(It may be necessary to clip the conduit
connector nut and flex it slightly to slide it over
the control harness connectors. Nut should still
be able to be tightened against cover plate.)
f. Locate mating connectors labeled “LWCO
Power” and “LWCO Contacts” inside left
junction box. Join mating connectors which
are polarized and lock together. Lightly tug on
connectors to make sure they are secure.
g. Proceed to next control option listed below for
installation details. If no other controls are being
installed at this time, secure cover ‘A’ and cover
‘B’ to jacket rear top panel with two (2) #8 x
1/2” lg. hex head SMS per cover.
Figure 41: Install Probe Low Water Cut Off
54
Install 7/8” knockout plugs (provided) to all
unused holes, refer to Figure 40.
2. Install High Limit Control w/Manual Reset
(L4006E)
a. Apply thread sealant to 3/4” immersion well
and install in Tapping ‘F’ as shown in Figure 38. Wrench well until water tight.
b. Locate L4006E High Limit Control and
remove knockout on casing closest to mounting
hole. Connect end of harness with forked
terminals to casing knockout. Connect orange
wires to terminals on limit control, wires are
interchangeable. Refer to Figure 42.
Figure 42: Install High Limit Control
c. Connect opposite end of L4006E High Limit
Control harness to left side junction box cover
‘B’, hole location #5 as shown in Figure 40.
d. Locate mating connector labeled “Limit” inside
left junction box. Join mating connectors which
are polarized and lock together. Lightly tug on
connectors to make sure they are secure.
e. Proceed to next appropriate control option
listed below for installation details. If no other
controls are being installed at this time, secure
Cover ‘A’ and Cover ‘B’ to jacket rear top panel
with two (2) #8 x 1/2” lg. hex head SMS per
cover. Install 7/8” knockout plugs (provided) to
all unused holes, refer to Figure 40.
3. Install Low Fire Hold Control (L4006B)
a. Apply thread sealant to 1/2” immersion well
and install in Tapping ‘J’ as shown in Figure 38. Wrench well until water tight.
b. Locate L4006B Low Fire Hold control and
remove knockout on casing closest to mounting
hole. Connect end of harness with forked
terminals to casing knockout. Connect blue
wires to terminals on limit control, wires are
interchangeable. Refer to Figure 43.
lg. hex head SMS per cover. Install 7/8”
knockout plugs (provided) to all unused
holes, refer to Figure 40.
b. Install Modulating Control as follows:
i. Apply thread sealant to 3/4” immersion
well and install in Tapping ‘H’ as shown in
Figure 38. Wrench well until water tight.
ii. Locate T991A Modulation control and
remove knockout on casing closest to
temperature control knob. Connect end
of harness with forked terminals to casing
knockout.
Figure 43: Install Low Fire Hold Control
c. Connect opposite end of L4006B Low Fire Hold
Control harness to right side junction box cover
‘A’, hole location #2 as shown in Figure 40.
d. Locate mating connector labeled “Low Fire
Hold” inside right junction box. Join mating
connectors which are polarized and lock
together. Lightly tug on connectors to make sure
they are secure.
e. Proceed to next appropriate control option
listed below for installation details. If no other
controls are being installed at this time, secure
Cover ‘A’ and Cover ‘B’ to jacket rear top panel
with two (2) #8 x 1/2” lg. hex head SMS per
cover. Install 7/8” knockout plugs (provided) to
all unused holes, refer to Figure 40.
4. Install Low/High/Low Control or Modulating
Control
a. Install Low/High/Low Control as follows (for
modulating control, proceed to Step b):
i. Apply thread sealant to 3/4” immersion
well and install in Tapping ‘H’ as shown in
Figure 38. Wrench well until water tight.
ii. Locate L4006A Low/High/Low Control
and remove knockout on casing closest to
mounting hole. Connect end of harness
with forked terminals to casing knockout. Connect black and gray wires to terminals
on Low/High/Low Control, wires are
interchangeable. Refer to Figure 44.
iii. Connect opposite end of L4006A Low/High/
Low Control harness to junction box cover
‘A’, hole location #4 as shown in Figure 40.
iv. Locate mating connector labeled “LO-HILO/MOD” inside right junction box. Join
mating connectors which are polarized and
lock together. Lightly tug on connectors to
make sure they are secure.
v. Proceed to next appropriate control option
listed below for installation details. If no
other controls are being installed at this
time, secure Cover ‘A’ and Cover ‘B’ to
jacket rear top panel with two (2) #8 x 1/2”
Figure 44: Install Low/High/Low Control
Connect wires to terminals as follows:
B Terminal - Black Wire w/White Tracer
W Terminal - Gray Wire
R Terminal - Red Wire w/White Tracer
iii. Install Remote Sensing Bulb into control
well and secure with retaining clip. Coil
excess sensor tubing as shown in Figure 45.
iv. Mount T991A Control to rear panel on
left side of return manifold with two (2)
self drilling #8 x 1/2” lg. hex head SMS
(provided) as shown in Figure 45.
Figure 45: Install Modulation Control
55
v. Connect opposite end of T991A Modulating
Control harness to right side junction box
cover ‘A’, hole location #4 as shown in
Figure 40.
vi. Locate mating connector labeled “LO-HILO/MOD” inside right junction box, see
Figure 40. Join mating connectors which
are polarized and lock together. Lightly tug
on connectors to make sure they are secure.
vii. If no other controls are being installed at
this time, secure Cover ‘A’ and Cover ‘B’
to jacket rear top panel with two (2) #8 x
1/2” lg. hex head SMS per cover. Install
7/8” knockout plugs (provided) to all unused
holes, refer to Figure 40.
T. Install Flue Outlet Damper Assembly, see Figure 46.
1. Locate flue outlet damper carton, as applicable (see
Table below). Open carton remove a flue outlet
damper assembly, a flue outlet damper gasket and
mounting hardware bag (12 pcs each 5/16 -18 x 7.8”
hex head plated cap screws and 1/4” USS plated
washers).
2. Assemble two cap screw/washer combinations,
then, insert cap screws/washers through a flue outlet
damper assembly-mounting ring at 3 o’clock and
9 o’clock positions. Place the flue outlet damper
gasket onto cap screws and position damper with
gasket onto boiler rear flue collector, aligning screws
with flue collector threaded holes.
3. Thread the screws at 3 o’clock and 9 o’clock
positions into flue collector threaded holes hand
tight.
4. Assemble remaining cap screw/washer
combinations, then, insert cap screws/washers
through a flue outlet damper assembly-mounting
ring/gasket and thread the screws into flue collector
threaded holes hand tight.
5. Alternately tighten the screws with an open end or
socket head wrench to complete the assembly.
Boiler Model
Flue Outlet Damper
Carton Part Number
Flue Outlet
Damper Diameter
Recommended Vent
Connection Size
MPC4 & MPC5
MPC6 thru MPC8
MPC9 thru MPC12
MPC13 thru MPC18
102473-01
102473-02
102473-03
102473-04
7” Dia.
8” Dia.
10” Dia.
12” Dia.
7” Dia.
8” Dia.
10” Dia.
12” Dia.
Figure 46: Install Flue Outlet Damper Assembly
56
U. Install Optional Split Jacket Panels for Burner Swing
Door (BSD) Cover (if applicable).
1. Open carton and remove contents.
2. Locate hanger bracket for BSD cover, secure to
jacket front panel with three (3) #8 x 1/2” hex head
SMS as shown in Figure 47.
3. Install left side BSD cover panel with offset bend as
shown in Figure 47. Engage hooks on outer edge of
panel through slotted openings on jacket front panel
installed on boiler. At the same time, engage top
flange of left cover panel behind hanger bracket, see
Figure 47, Detail ‘A’. Pull down on left cover panel
to lock hooks in slots and top flange behind hanger
bracket.
4. Install right side BSD cover panel using the same
procedure used on left cover panel. Before locking
panel in place, make sure right cover panel overlaps
offset flange of left cover panel.
5. Secure panels together at seam using six (6) #8 x
1/2” lg. hex head SMS, one (1) screw on top and
five (5) screws on the face as shown in Figure 47.
6. Locate Logo Plate shipped in Instruction Envelope. Peel paper off adhesive strips and install by inserting
positioning tabs on rear of Logo Plate into slotted
openings in upper left corner of left cover panel as
shown in Figure 47.
Figure 47: Install Jacket Panels for Optional Burner Swing Door Cover
57
SECTION IV - INSTALLATION INSTRUCTIONS
A. PACKAGED BOILER
1. The packaged boiler comes on its own shipping
skid (see Figure 48) and the assembled block is
hydrostatically tested at the factory. Once the boiler
is in its final position, perform another hydrostatic test at 1½ times the working pressure of the boiler (see
Section II, Paragraph C). The shipping skid can be
used as a housekeeping pad unless local codes say
otherwise. Most controls are pre-wired down to the
burner. If burner is equipped with a lead lag panel,
lead lag controls will be shipped loose for header
mounting. The power can be supplied to the burner
if equipped with a control panel. If burner has no
panel, the power must be supplied to a junction box
near the front of the boiler.
2. If the boiler burner unit was factory fire tested,
the burner was adjusted to approximately 10.2%
CO2 (gas) or 13.2% CO2 (oil) with an overfire
pressure as listed in Table II of this manual. Final
adjustments should be made once the unit is
installed.
B. BOILER PIPING - HEATING APPLICATIONS
CONNECT SUPPLY AND RETURN PIPING TO
HEATING SYSTEM (see Figures 49a, 49b, 50a and
50b).
WARNING
Failure to properly pipe boiler may result in
improper, unsafe system operation and void
manufacturer’s warranty.
DO NOT improperly pipe boiler.
WARNING
All hot water pipes must have clearances of at
least 1/2” from all combustible construction.
WARNING
A hot water boiler installed above radiation level
must be provided with a low water cutoff device
as part of the installation.
1. HOT WATER HEATING - This boiler must be
installed in strict accordance to the instructions
found in this installation manual. Deviations
from these installation instructions may void
manufacturer’s warranty.
Packaged Boiler Shipping Information
Number of
Sections
Length
A
(Inch)
Width
B*
(Inch)
Height
C
(Inch)
Approx.
Center of
Gravity D
** (Inch)
Approx.
Shipping
Weight
(Lbs.)
4
77½
48
61½
23¼
2789
5
83½
48
61½
26¼
3272
6
95½
48
61½
29¼
3755
7
101¾
48
61½
32½
4249
8
108
48
61½
35½
4783
9
114
48
61½
38½
5261
10
130¼
48
61½
44½
5757
11
136½
48
61½
47¾
6236
12
142½
48
61½
50¾
6739
13
148½
48½
61½
53¾
7227
14
154¾
48½
63½
57
7760
15
161
48½
63½
60
8335
16
167
48½
63½
63
8824
17
173
48½
63½
66
9324
18
179¼
48½
63½
69¼
9823
* Width can vary with gas train configuration.
** Varies slightly with burner and gas train configuration.
1. Do not tilt. Exercise caution when lifting to avoid
damage.
2. This boiler can be lifted by fork truck. Do not truck from
front.
3. When lifting from rear, forks must extend from beyond
center of gravity and second skid cross bar.
4. When lifting from side, forks must extend to opposite
skid rail and straddle center of gravity.
5. Cablespreader is to prevent jacket damage. Spreader
width should equal B (width of skid) + 12”. Adjust cable
lengths to lift at approximate center of gravity per chart.
Figure 48: Packaged Boiler Shipping Information
58
Boiler Operating Requirements:
• Minimum Return Water Temperature = 80°F
• Maximum Delta T = 80°F
• Minimum Supply Water Temperature = 130°F
1 Supply
Boiler
Model
MPC4
/
2 Return
20°F Rise
Water Side
Nom. I.D.
Press. Drop
(Inch)
(Ft/Wtr)
2
1.9
NOTES:
1. All piping is schedule 40.
40°F Rise
Flow
Rate
(GPM)
42.4
Water Side
Nom. I.D.
Press. Drop
(Inch)
(Ft/Wtr)
1½
0.9
Flow
Rate
(GPM)
21.2
MPC5
2
2.6
65.2
1½
1.6
32.6
MPC6
2
3.3
83.7
1½
2.3
41.9
MPC7
2½
4.0
102.3
1½
3.0
51.2
MPC8
2½
4.7
120.9
2
3.7
60.5
MPC9
3
5.4
139.6
2
4.4
69.8
MPC10
3
6.1
158.1
2
5.1
79.0
MPC11
3
6.8
176.7
2
5.8
88.3
MPC12
3
7.5
195.2
2½
6.4
97.6
MPC13
4
8.2
213.8
2½
7.1
106.9
MPC14
4
8.9
232.3
2½
7.8
116.1
MPC15
4
9.6
250.9
2½
8.5
125.5
MPC16
4
10.3
269.5
3
9.2
134.8
MPC17
4
11.0
288.1
3
9.9
144.1
MPC18
4
11.7
306.6
3
10.6
153.3
2. Pipe sizes listed are based on a 20°F
or 40°F Delta T (temperature rise
across the boiler).
Select one to match application.
3. When specified supply/return piping
size is less than 4”, install appropriate
size reducer directly onto boiler supply
and return manifolds.
4. Drain valve - ball valve preferable,
gate valve acceptable alternative
(supplied by others). Minimum valve
size per ASME Code is 3/4” NPT.
5. Swing joints may be piped over the top
of the boiler if space is limited.
6. System design must accommodate the
above Boiler Operating Requirements.
7. Diaphragm expansion tank shown, but
other types of air elimination systems
may be used.
Figure 49a: Recommended MPC Minimum Piping - Single Boiler Application
59
60
Figure 49b: Recommended MPC Minimum Piping - Multiple Boiler Application
• Minimum Return Water Temperature = 80°F
• Maximum Delta T = 80°F
• Minimum Supply Water Temperature = 130°F
Boiler Operating Requirements:
NOTES: For Boiler pipe sizes, flow rates, pressure drops and other important information and notes, refer to Figure 49a.
Boiler Operating Requirements:
• Minimum Return Water Temperature = 80°F
• Maximum Delta T = 80°F
• Minimum Supply Water Temperature = 130°F
1 Supply
Boiler
Model
MPC4
/
2 Return
20°F Rise
Water Side
Nom. I.D.
Press. Drop
(Inch)
(Ft/Wtr)
2
1.9
40°F Rise
Flow
Rate
(GPM)
42.4
Water Side
Nom. I.D.
Press. Drop
(Inch)
(Ft/Wtr)
1½
0.9
Flow
Rate
(GPM)
21.2
MPC5
2
2.6
65.2
1½
1.6
32.6
MPC6
2
3.3
83.7
1½
2.3
41.9
MPC7
2½
4.0
102.3
1½
3.0
51.2
MPC8
2½
4.7
120.9
2
3.7
60.5
MPC9
3
5.4
139.6
2
4.4
69.8
MPC10
3
6.1
158.1
2
5.1
79.0
MPC11
3
6.8
176.7
2
5.8
88.3
MPC12
3
7.5
195.2
2½
6.4
97.6
MPC13
4
8.2
213.8
2½
7.1
106.9
MPC14
4
8.9
232.3
2½
7.8
116.1
MPC15
4
9.6
250.9
2½
8.5
125.5
MPC16
4
10.3
269.5
3
9.2
134.8
MPC17
4
11.0
288.1
3
9.9
144.1
MPC18
4
11.7
306.6
3
10.6
153.3
NOTES:
1. All piping is schedule 40.
2. Pipe sizes listed are based on a 20° F
or 40° F Delta T (temperature rise
across the boiler).
Select one to match application.
3. When specified piping size is less than
4”, install appropriate size reducer
directly onto boiler supply and return
manifolds.
4. Drain valve - ball valve preferable,
gate valve acceptable alternative
(supplied by others). Minimum valve
size per ASME code is 3/4” NPT.
5. Swing joints may be piped over the top
of the boiler if space is limited.
6. System design must accommodate the
above Boiler Operating Requirements.
7. Diaphragm expansion tank shown, but
other types of air elimination systems
may be used.
Figure 50a: Alternate MPC Minimum Piping - Single Boiler Application
61
62
Figure 50b: Alternate MPC Minimum Piping - Multiple Boiler Application
• Minimum Return Water Temperature = 80°F
• Maximum Delta T = 80°F
• Minimum Supply Water Temperature = 130°F
Boiler Operating Requirements:
NOTES: For Boiler pipe sizes, flow rates, pressure drops and other important information and notes, refer to Figure 50a.
a. Temperature and Flow Requirements – An
existing parallel piping system may be used,
provided the return water is not below 80°F and
the return water temperature is not more than
80°F less than the boiler outlet temperature. A
flow analysis should be performed to determine
the flow through the boiler when the minimum
(and smallest) and maximum number of zones
are activated. Sufficient flow through the boiler must be
maintained. The recommended maximum
temperature difference between the boiler supply
and return water is 40°F. However, a maximum
delta T of 80°F across the boiler is allowable. A minimum boiler supply water temperature of
130°F must be maintained to avoid sustained
condensing within the combustion chamber.
b. Primary/Secondary Piping - If the conditions
above cannot be met, then parallel piping
systems must be converted to an arrangement
that will provide the proper water flow through
the boiler at the proper temperatures. Primary/
Secondary piping is a common method for
isolating the boiler from the system. The
concept must be for the boiler loop to inject
heat into a primary loop, provided the return
water into the boiler is at least 80°F. A by-pass
containing two closely spaced tees must be
installed to de-couple the boiler loop from the
primary loop (see Figure 51). The converted
system should resemble Figure 52. Care must
be taken to avoid dead heading the system pump. Conversions should be reviewed and approved
by a Consulting Engineer or other qualified
professional to avoid system deficiencies.
Figure 52: Typical Burnham Boiler Primary - Secondary Loop System
c. Alternate Piping Arrangements - Piping
arrangements other than Parallel and Primary/
Secondary, such as System Bypass, are
acceptable as long as they ensure that the flow
and temperature requirements of the boiler are
met.
d. Glycol Antifreeze Solutions - Many systems
today use ethylene or propylene glycol antifreeze
solutions as a measure for freeze protection, as
well as a pump lubricator and corrosion inhibitor. The properties of the glycol mixture have an
impact on valve and pump sizing. All glycol
solutions have a lower specific heat than water.
This means that the glycol solution cannot
transfer heat as well as pure water, resulting in
the need for higher flow rates. In addition, the
viscosity of the glycol solution is usually higher
than water, requiring a higher pump head for the
same given flow. Consult factory for specific
applications, pump selection and flow rate.
e. 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 53.
Figure 51: Parallel Piping Conversion
Multiple boilers are installed the same as single
boiler installations. Each boiler loop will contain
its own boiler circulator (see Figure 49b).
The boiler circulator selection will maintain a
constant and minimum flow through the boiler
during every heat demand. The circulator
must be properly selected, based on the design
temperature between the boiler supply and boiler
return. A boiler circulator must be used with a
primary/secondary piping arrangement.
Figure 53: Recommended Piping for Combination
Heating & Cooling (Refrigeration) Systems
63
NOTICE
When possible, domestic hot water production should utilize dedicated boiler(s). This will allow the other
boiler(s) to be shut down and isolated during the summer months. If the boiler load is shared between
heating and domestic hot water, then one needs to determine if a hot water priority is required. If a priority
is not selected, erratic domestic hot water production may result during the beginning and end of every
heating season. Conversely, a priority for domestic hot water production may cause a significant heating
zone activation delay, in an improperly balanced system. Parallel piping conversions may require isolation
from the heating system to prevent system flow influence on DHW performance. Consult a qualified system
heating professional to design for the proper application.
C. BOILER PIPING, DOMESTIC HOT WATER
(DHW) APPLICATION – The MPC boiler can be
used in many different piping applications to produce
Domestic Hot Water (DHW). In some applications,
depending on the control strategy (outdoor reset,
setpoint operation, etc.) and size of the boiler, it is
recommended to isolate the space heating load from the
DHW load. For example, if the domestic load is more
than the space heating load, it is beneficial to dedicate
one or more boilers solely to DHW production and one
or more boilers solely to space heating, since during
mild weather conditions, the boiler(s) will have more
capacity than is required. Piped in the recommended
manner, the space heating boiler(s) can be shut down
during the summer months to conserve energy and to
avoid short cycling.
The use of indirect water heaters for domestic
hot water generation is commonly recommended
since they provide DHW storage. A tempering
valve and recirculation loop are advantageous in
these applications, because they provide both high
temperature and tempered domestic water to the
system, eliminating the need to purge and waste water
until it reaches the desired temperature. See Figures
49a, 49b, 50a and 50b for recommended indirect water
heater piping.
NOTICE
DO NOT use the boiler circulator as an indirect
domestic hot water system circulator.
D. Relief Valve Discharge Piping, see
Figure 54. Pipe discharge to within 4” of floor or to a
suitable drain. Do not reduce piping size or install shutoff valve in discharge piping.
If discharge is weeping, do not plug relief valve or cap
discharge piping, replace valve immediately.
E. INSTALL ELECTRIC WIRING in accordance
with National Electric Code and local regulations. A
separate ELECTRICAL CIRCUIT should be run from
meter with a Fused Disconnect Switch in this Circuit.
Figure 54: Discharge Piping for Pressure Relief Valve
64
SECTION V - OPERATING INSTRUCTIONS
i. Close hose bib, continue filling the system until
the pressure gauge registers normal system
design operating pressure. Close fill valve.
(Note - If make-up water line is equipped
with pressure reducing valve, system will
automatically fill to normal system design
operating pressure. Leave globe valve open).
j. Open isolation valve in boiler supply piping.
k. Remove hose from hose bib.
WARNING
If you do not follow these instructions exactly,
a fire or explosion may result causing property
damage or personal injury.
If any unusual or improper operation or site conditions are observed, turn the boiler off and contact
an experienced and skilled service agency.
Follow component manufacturer’s instructions.
Component manufacturer’s instructions were
provided with the boiler. Contact component
manufacturer for replacement if instructions
are missing. Do not install, start up, operate,
maintain or service this boiler without reading and
understanding all of the component instructions.
Do not allow the boiler to operate with altered,
disconnected or jumpered components. Only
use replacement components identical to those
originally supplied with the boiler and burner.
DANGER
Do not operate boiler with pressure above
maximum allowable working pressure listed on
the Boiler’s ASME Data Label.
DO NOT draw water from boiler while in use.
When adding water while boiler is in operation,
do not open supply valve fully but add water
slowly.
C.SET CONTROLS with burner service switch turned
“OFF”.
A. ALWAYS INSPECT INSTALLATION BEFORE
1. PRESS RESET BUTTON on primary control and
release.
STARTING BURNER.
B.FILL HEATING SYSTEM WITH WATER.
2. BOILER OPERATING AQUASTAT - The
operating aquastat, L4006A should be set to the
designed supply temperature, typically 180°F.
1. CLEAN HEATING SYSTEM IF boiler water
is dirty. Refer to step (F) for proper cleaning
instructions for water boilers.
Fill entire Heating System with water and vent air
from system. Use the following procedure on a
Series Loop or Multi-zoned System to remove air
from system when filling:
a. Close isolation valve in boiler supply piping.
b. Isolate all circuits by closing zone valves or
balancing valves.
c. Attach a hose to hose bib located just below
isolation valve in boiler supply piping.
(Note - Terminate hose in five gallon bucket at a
suitable floor drain or outdoor area).
d. Starting with one circuit, open zone valve.
e. Open hose bib.
f. Open fill valve (Make-up water line should be
located directly above isolation valve in boiler
supply piping.
g. Allow water to overflow from bucket until
discharge from hose is bubble free for 30
seconds.
h. Open zone valve to the second zone to be
purged, then close the first. Repeat this step until
all zones have been purged, but always have one
zone open. At completion, open all zone valves.
3. BOILER HIGH LIMIT AQUASTAT - The high
limit aquastat, L4006E, can be identified with a red
manual reset button. Ideally, the high limit aquastat
should be set high enough above the operating
aquastat setting so as to avoid nuisance shutdowns
on manual reset. The temperature must be set below
the maximum permissible temperature for any
system related component affected by boiler supply
water. Under no circumstances can the high limit
aquastat be set higher than 250°F.
D. ADJUST BURNER according to the Burner Manual.
The MPC boiler controls operate the burner
automatically. If for unknown reasons the burner
ceases to fire and the reset button on the primary control
is tripped, the burner has experienced ignition failure. Before pressing the reset button, call your serviceman
immediately.
WARNING
Do not attempt to start the burner when excess
oil or gas has accumulated in the combustion
chamber, when the unit is full of vapor, or when
the combustion chamber is very hot.
65
E. TEST CONTROLS
WARNING
Before installation of the boiler is considered
complete, the operation of the boiler controls
should be checked, particularly the low water
cutoff and the high limit control.
1. CHECK OPERATING CONTROL OPERATION.
Raise and lower operating control setting as required
to start and stop burner.
2. CHECK OPERATION OF HIGH LIMIT
CONTROL.
Jumper operating control terminals. Allow burner to
operate until shutdown by limit. Installation is not
considered complete until this check has been made.
REMOVE JUMPER.
3. CHECK LOW WATER CUTOFF CONTROL Raise operating control setting to allow burner to
operate. Close isolation valves in supply and return
near boiler piping. Open boiler drain to allow water
level to drop until burner operation is shut down by
low water cutoff. If necessary, open relief valve for
air to facilitate draining.
Close boiler drain and refill boiler. Burner should
automatically restart during fill, unless low water
cutoff control requires manual reset. Close relief
valve when water flows out discharge piping.
open supply and return isolation
valves.
Reset operating control.
CAUTION
Probe and float type low water cutoff devices
require annual inspection and maintenance.
Refer to Section VI step (C) for proper cleaning
instructions.
F. BOILER AND SYSTEM CLEANING (water side)
NOTICE
A qualified water treatment chemical specialist
should be consulted for recommendations
regarding appropriate chemical compounds and
concentrations which are compatible with local
environmental regulations.
66
WARNING
Chemicals used in treating boiler water are
toxic and/or harmful. Always use protective
clothing and equipment when working with/
near chemicals. Contact local authorities
to determine if treated boiler water can be
discharged into local waste water system.
1. Filling of Boiler and System --- General --- In a hot
water heating system, the boiler and entire system
(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
normal system design operating pressure. 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. Remove safety relief valve using extreme care to
avoid damaging it.
b. Add an appropriate amount of recommended
boilout compound.
c. Reinstall safety relief valve.
d. Fill the entire system with water.
e. Start firing the boiler.
f. Circulate the water through the entire system.
g. Vent the system, including the radiation.
h. Allow boiler water to reach operating temperature, if possible.
i. Continue to circulate the water for a few hours.
j. Stop firing the boiler.
k. Drain the system in a manner and to a location
that hot water can be discharged with safety.
l. Remove plugs from all available returns and
wash the water side of the boiler as thoroughly as
possible, using a high-pressure water stream.
m.Refill the system with fresh water.
3. Add appropriate boiler water treatment compounds
as recommended by your local qualified water
treatment company.
4. Make pH or Alkalinity Test.
After boiler and system have been cleaned and
refilled 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
specific readings. A color chart on the side of the
small hydrion dispenser gives the reading in 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 some appropriate water treatment chemicals,
if necessary, to bring the pH within the specified
range. With this lower level of protection, care must
be exercised to eliminate all of the free oxygen in
the system. H. OXYGEN CORROSION:
WARNING
Oxygen contamination of the boiler water
will cause corrosion of iron and steel boiler
components, and can lead to boiler failure.
Burnham’s standard warranty does not cover
problems caused by oxygen contamination of
boiler water or scale (lime) build-up caused by
frequent addition of water.
5. Boiler is now ready to be put into service.
G.FREQUENT WATER ADDITION
IMPORTANT
IF, DURING NORMAL OPERATION, IT IS NECESSARY TO ADD WATER MORE FREQUENTLY
THAN ONCE A MONTH, CONSULT A QUALIFIED
SERVICE TECHNICIAN TO CHECK YOUR
SYSTEM FOR LEAKS.
A leaky system will increase the volume of make-up
water supplied to the boiler which can significantly
shorten the life of the boiler. Entrained in make-up
water are dissolved minerals and oxygen. When the
fresh, cool make-up water is heated in the boiler the
minerals fall out as sediment and the oxygen escapes
as a gas. Both can result in reduced boiler life. The
accumulation of sediment can eventually isolate
the water from contacting the cast iron. When this
happens the cast iron in that area gets extremely hot
and eventually cracks. The presence of free oxygen in
the boiler creates a corrosive atmosphere which, if the
concentration becomes high enough, can corrode the
cast iron through from the waterside. Since neither of
these failure types are the result of a casting defect the
warranty does not apply. Clearly it is in everyone’s best
interest to prevent this type of failure. The maintenance
of system integrity is the best method to achieve less
makeup water.
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 fittings.
c. Oxygen permeable materials in the distribution
system.
d. Suction at pump and valve seals.
In order to ensure long product life, oxygen sources
should 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 fittings 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.
67
SECTION VI - SERVICE INSTRUCTIONS
DANGER
This boiler used flammable gas, high voltage electricity, moving parts, and very hot water under high
pressure. Assure that all fuel and electric power supplies are off and that the water temperature is cool
before attempting any disassembly or service.
More than one gas shut-off valve and electrical disconnect switch are used on the boiler. Assure that
all gas valves and electrical disconnect switches are off before attempting any disassembly or service.
Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify,
remove or tamper with any control device.
WARNING
This boiler must only be serviced and repaired by skilled and experienced service technicians.
If any controls are replaced, they must be replaced with identical models.
Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.
If any electrical wires are disconnected during service, clearly label the wires and assure that the wires
are reconnected properly.
NEVER operate boiler without all sight glasses and brackets in place and securely fastened and sealed.
Very HOT combustion gas may cause burn injury.
Read, understand and follow all the instructions and warnings contained in ALL of the component
instruction manuals.
Assure that all safety and operating controls and components are operating properly before placing
the boiler back in service.
IMPORTANT - See Section V, Item (G) under
Operating Instructions, if it becomes necessary to add
water to the boiler more frequently than once a month.
A. GENERAL - Inspection should be conducted annually. Service as frequently as specified in following
paragraphs. Refer to Table XII for recommended
periodic testing of safety controls and other equipment.
While service or maintenance is being done, electrical
power to the boiler must be “off”.
B.CLEAN THE BOILER HEATING SURFACES
AND FLUE at least once each year, preferably at the
end of the heating season.
1. CLEAN THE VENT SYSTEM - Vent system should
be checked annually for:
a. Obstructions.
b. Accumulations of soot.
c. Deterioration of vent pipe or vent accessories
due to condensation or other reasons. d. Proper support - no sags, particularly in
horizontal runs.
e. Tightness of joints.
68
Remove all accumulations of soot with wire
brush and vacuum. Remove all obstructions. Replace all deteriorated parts and support
properly. Seal all joints.
2. CLEAN THE BOILER FLUEWAYS AND
COMBUSTION CHAMBER.
a. Disconnect the fuel line(s) and remove the
burner. The burner may remain attached to the
BSD during cleaning if:
i. enough space exists for the BSD to swing
open completely with the burner still
attached
ii. and the burner weight is supported by a
suitable prop at all times.
b. Remove optional BSD cover panels (if
provided).
c. Remove four (4) 9/16” cap screws and lock
washers from the hinge pockets on the BSD.
d. Open the BSD and remove the baffles from all
flue passages.
e. Use a wire or fiber bristle brush to remove any
accumulated soot or debris from all of the flue
baffles.
f. Use a wire or fiber bristle brush of appropriate
length and diameter to allow sufficient cleaning
of all flue passages. Using long strokes, push the
brush the whole way through the boiler and then
pull it out. Repeat this process until all surfaces
of each of the flue passages have been cleared of
all soot and debris.
g. Vacuum all loose debris that has collected in
the rear of the combustion chamber and in the
turnaround passages into the second flue passes.
h. Use a wire or fiber bristle brush to clean all of
the surfaces of the combustion chamber and
turnaround passages to the second flue passes.
i. Vacuum all loose debris in the bottom of the
combustion chamber and in the turnaround
passages to the second flue passes.
j. Remove the flue collector clean-out covers at
the rear of the boiler by removing four (4) 5/16”
cap screws and washers. Through these cleanout openings, vacuum all loose debris from the
bottom of the flue collector.
3. REASSEMBLE BOILER.
a. Reattach the flue collector clean-out covers to
the rear of the boiler, verifying that the siliconecoated rope gaskets are still in satisfactory
condition. Replace the rope gaskets, if
necessary, before reassembly. Tighten the covers
snugly into place using original 5/16” hardware. Do not over tighten.
b. Insert the flue baffles into the appropriate flue
passes.
c. Inspect the insulation and silicone-coated rope
gasket on the inside of the BSD, making sure
that everything is in place and undamaged. If
the BSD insulation or rope gasket is damaged,
replace them.
d. Carefully close the BSD and secure it in place
using the original 9/16” hardware. When
tightening the bolts, make sure that the BSD
is drawn in equally at all four corners. Use an
alternating tightening method from corner to
corner to pull the door tight equally around the
perimeter.
NOTICE
Do not overtighten. The rope gasket will provide
sufficient seal when the door is snugged in
place.
e. Reinstall the burner to the BSD (if removed) and
secure it in place on its support pedestal. Inspect
the burner gasket to assure an adequate seal. Replace it if damaged.
f. Connect the fuel lines.
g. Reattach the BSD cover panels (if provided).
CAUTION
Do not start the burner unless BSD, smokepipe,
flue clean-out covers and burner are all secured
in place.
C. MAINTENANCE OF LOW WATER CUTOFF
DEVICES
NOTICE
Probe and float type low water cutoff devices
require annual inspection and maintenance.
1. PROBE TYPE LOW WATER CUTOFF
Although these devices are solid state in their
operation, the probe is exposed to possible
contamination in the boiler water and subject to
fouling. It is important to physically remove the
probe from the boiler 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. Close isolation valves in supply and return near
boiler piping.
c. Drain boiler water to a level below the tapping
for the probe.
d. Disconnect wiring connections between the low
water cutoff control and the probe.
DANGER
Assure that the boiler is at zero pressure before
removing the LWCO probe. Do not rely on the
pressure gauge to indicate that the boiler is at
zero pressure. Open the relief valve to relieve
all internal pressure prior to proceeding. Relief
valve discharge piping must be piped such that
the potential for burns is eliminated.
e. Dismount the low water cutoff control from the
probe.
f. Unscrew the probe from the boiler tapping.
g. Inspect that portion of the probe that is exposed
to the boiler water for a scale or sediment
buildup.
h. 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 part of water to 1 part)
of phosphoric acid (H2PO4).
69
WARNING
Exercise caution when handling phosphoric acid
and follow the instructions on container label.
Always use protective clothing and equipment
when working with/near chemicals.
i. Wire brushing of the probe is not recommended
as the soft platinum guard ring sandwiched
between the ceramic insulators may be damaged. Care must be taken not to damage this ring in
any way or the useful life of the probe may be
shortened.
j. Clean the pipe threads of the probe to remove
old, hardened pipe dope and other foreign matter.
k. 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 (Teflon)
tape.
l. Screw the probe into the boiler tapping.
m.Mount the low water cutoff control on the probe.
n. Reconnect the control to probe wiring.
o. Fill the boiler.
p. Add boiler water treatment compound as needed.
q. Restore electric service to the boiler.
r. Fire burner to bring the water in the boiler to a
boil to drive off free oxygen. s. BEFORE RETURNING BOILER TO
SERVICE: Follow the low water cutoff check
out procedure, see Section V, Paragraph E, Item
3.
2. FLOAT TYPE LOW WATER CUTOFF
During the heating season, if an external low water
cutoff is on the boiler, the blow off valve should
be opened once a month (use greater frequency
where conditions warrant), to flush out the sediment
chamber so the device will be free to function
properly.
Low water cutoffs should be dismantled annually by
qualified personnel, to the extent necessary to insure
freedom from obstructions and proper functioning of
the working parts. Inspect connecting lines to boiler
for accumulation of mud, scale, etc., and clean as
required. Examine all visible wiring for brittle or
worn insulation and make sure electrical contacts
are clean and that they function properly. Give
special attention to solder joints on bellows and float
when this type of control is used. Check float for
evidence of collapse and check mercury bulb (where
applicable) for mercury separation or discoloration. DO NOT ATTEMPT TO REPAIR MECHANISMS
IN THE FIELD. 70
Complete replacement mechanisms, including
necessary gaskets and installation instructions, are
available from the manufacturer.
D.Check burner and controls at least once
a year. See Section V, Paragraph E under Operating
Instructions for control checks. See Burner Manual
and Table XII for recommended burner tests and
adjustments.
E. LUBRICATE BOILER COMPONENTS according
to manufacturer’s instructions. Generally, this involves
the burner and circulator. This includes the type of
lubricant to use, frequency of lubrication, and points to
lubricate.
F. GENERAL MAINTENANCE
CONSIDERATIONS
1. Keep radiators and convectors clean.
2. If a hot water radiator is hot at the bottom but not at
the top, it indicates that air has accumulated inside
and should be vented. To vent radiator, hold small
cup under air vent (located near top of radiator),
open vent until water escapes and then close.
3. If a large volume of water is added to the system, it
is advisable to heat the system to a high temperature
and vent again. This will make less venting
necessary during the winter.
4. Where an expansion tank is used, make sure that
neither the tank nor its drain pipe is exposed to
freezing temperatures. Never place valves in piping
leading to or from expansion tank.
5. Boiler and system cleaning will help assure trouble
free operation. See Section V, Paragraph F, under
Operating Instructions for procedure.
G. ATTENTION TO BOILER WHILE NOT IN
OPERATION
WARNING
If boiler is not used during winter time, it must be
fully drained to prevent freeze damage.
1. Spray inside surfaces with light lubricating or
crankcase oil using a gun with an 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 V - Operating Instructions.
Table XII: Recommended Periodic Testing Check List
Item
Frequency
Accomplished by
Remarks
Gauges and Indicators
Daily
Operator
Make visual inspection and record
readings in log
Instrument and Equipment
Settings
Daily
Operator
Make visual check against
recommended specifications
Firing Rate Control
Weekly
Semiannually
Annually
Operator
Service Technician
Service Technician
Verify factory settings
Verify factory settings
Check with combustion test
Flue, Vent, Stack, or
Outlet Dampers
Monthly
Operator
Make visual inspection of linkage;
Check for proper operation
Igniter
Weekly
Operator
Make visual inspection; Check flame
signal strength if meter-fitted (See
“Combustion Safety Controls”)
Pilot and Main
Weekly
Operator
Open limit switch; Make aural and
visual check; Check valve position
indicators and fuel meters, if so
fitted
Pilot and Main Gas or Main Oil
Annually
Service Technician
Perform leakage tests
(Refer to burner instructions)
Weekly
Operator
Close manual fuel supply for (1)
pilot, (2) main fuel cock, and/or
valve(s); Check safety shutdown
timing; Record in Log
Weekly
Operator
Pilot Turndown Tests
As required / annually
Service Technician
Required after any adjustments to
flame scanner mount or pilot burner;
Verify annually (Refer to burner
instructions)
Hot Refractory Hold-In
As required / annually
Service Technician
See “Pilot Turndown Tests”
Low Water Cutoff and Alarm
Daily / Weekly
Semiannually
Operator
Operator
Refer to instructions
Perform a slow drain test in accordance with ASME Boiler and Pressure Vessel Code Section VI
Fuel Valves
Combustion Safety Controls
Flame Failure
Flame Signal Strength
If flame signal meter installed, read
and log; For both pilot and main
flames, notify service organization if
readings are very high, very low, or
fluctuating (Refer to burner instructions)
(continued)
71
Table XII: Recommended Periodic Testing Check List (continued)
Item
72
Frequency
Accomplished by
Remarks
High Limit Safety Control
Annually
Service Technician
Refer to instructions
Operating Control
Annually
Service Technician
Refer to instructions
Low Draft, Fan, Air
Pressure, and Damper
Position Interlocks
Monthly
Operator
Refer to burner instructions
High and Low Gas
Pressure Interlocks
Monthly
Operator
Refer to burner instructions
High and Low Oil
Pressure Interlocks
Monthly
Operator
Refer to burner instructions
High and Low Oil
Temperature Interlocks
Monthly
Operator
Refer to burner instructions
Fuel Valve Interlock
Switch
Annually
Service Technician
Refer to burner instructions
Purge Switch
Annually
Service Technician
Refer to burner instructions
Burner Position Interlock
Annually
Service Technician
Refer to burner instructions
Burner Rotary Cup
Interlock
Annually
Service Technician
Refer to burner instructions
Low Fire Start Interlock
Annually
Service Technician
Refer to burner instructions
Automatic Fuel
Changeover Control
(Dual Fuel)
At least annually
Service Technician
Under supervision of gas utility
Safety Relief Valve
As required
Operator
In accordance with procedure in Section
VI, ASME Boiler and Pressure Vessel
Code, Recommended Rules for Care
and Operation of Heating Boilers
Burner Components
Inspection
Semiannually
Service Technician
Refer to burner instructions
SECTION VII - BURNER SPECIFICATIONS
NOTICE
MPC boiler ratings and capacities are based upon the following burners, pump pressures, nozzle sizes and
manifold pressures. Refer to instructions furnished with burner for additional information regarding proper
installation, fuel piping, wiring details, burner adjustments, service instructions and burner start-up.
Table XIIIa: Beckett #2 Oil Burner Specifications
BURNER BURNER
BOILER
MIN.
MAX.
BURNER
MODEL
INPUT
INPUT
MODEL
(GPH)
(GPH)
BURNER SETTINGS
AIR
TUBE
COMB.
LOW FIRE HIGH FIRE
HEAD
AIR OR
AIR OR
SHUTTER
BAND
PUMP
PRESSURE
(PSI)
LOW
FIRE
HIGH
FIRE
NOZZLE
DATA
NOZZLE
MAKE
GPH X
ANGLE
- TYPE
MPC4
1.75
3.55
CF500
CF60KK
3
10
2
N/A
150
Delavan
2.75 X 70 - B
MPC5
3.0
5.5
CF800
CF60KH
3
8.5
0
N/A
150
Delavan
4.50 X 70 - B
MPC6
4.0
7.1
CF1400
CF66KD
4
43
48
150
250
Delavan
4.50 X 60 - B
MPC7
4.0
8.7
CF1400
CF66KE
6
45
51
150
300
Delavan
5.00 X 45 - B
MPC8
7.0
10.2
CF2300
CF66KG
1
37
47
150
300
Delavan
6.00 X 45 - B
MPC9
7.0
11.8
CF2300
CF66KG
7
39
41
150
295
Hago
7.00 X 45 - P
MPC10
7.0
13.4
CF2300
CF66KG
9
43
54
140
280
Delavan
8.00 X 45 - B
MPC11
10.0
15.0
CF2500
CF66KP
2
22
35
275
275
Hago
4.50 X 45 - P
MPC12
10.0
16.6
CF2500
CF66KP
2
23
41
300
300
Hago
5.00 X 45 - P
MPC13
10.0
18.2
CF2500
CF66KP
5
24
38
300
300
Hago
5.50 X 45 - P
MPC14
10.0
19.8
CF2500
CF66KP
6
26
43
275
275
Hago
6.00 X 45 - P
MPC15
10.0
21.5
CF2500
CF66KP
9
25
40
270
270
Hago
6.50 X 45 - P
MPC16
17.0
23.0
CF3500
CF114KR
7
29
42
275
275
Hago
7.00 X 45 - P
MPC17
17.0
24.5
CF3500
CF114KR
8
30
51
275
295
Hago
7.50 X 45 - P
MPC18
17.0
26.0
CF3500
CF114KR
8
29
68
265
265
Hago
8.00 X 45 - P
Table XIIIb: Beckett Gas Burner Specifications
BOILER
MODEL
BURNER BURNER
MIN.
MAX.
INPUT
INPUT
(MBH)
(MBH)
BURNER
MODEL
MANIFOLD PRESSURE
(“WC)
LOW
FIRE
HIGH
FIRE
SHUTTER
BAND
LOW FIRE
(START)
HIGH
FIRE
MINIMUM
INLET
PRESSURE
(“WC)
DAMPER SETTINGS
MPC4
300
500
CG10.3
N/A
N/A
6
0
1.0
1.8
2.80
MPC5
300
773
CG10.5
N/A
N/A
10
0
1.6
3.2
4.80
MPC6
350
995
CG15.2
26
45
N/A
N/A
1.15
3.15
4.30
MPC7
350
1216
CG15.3
29
66
N/A
N/A
1.1
3.5
4.60
MPC8
550
1438
CG25.1
16
45
N/A
N/A
1.1
3.6
4.70
MPC9
550
1660
CG25.2
22
53
N/A
N/A
0.8
3.57
4.37
MPC10
550
1881
CG25.3
25
54
N/A
N/A
0.75
3.4
4.15
MPC11
550
2103
CG25.4
27
52
N/A
N/A
0.9
3.6
4.50
MPC12
730
2325
CG50.1
28
72
N/A
N/A
0.9
4.2
5.10
MPC13
730
2547
CG50.2
20
39
N/A
N/A
0.8
3.6
4.40
MPC14
730
2769
CG50.3
22
39
N/A
N/A
0.7
3.4
4.10
MPC15
730
2991
CG50.3
22
44
N/A
N/A
0.65
4.0
4.65
MPC16
730
3213
CG50.3
21
46
N/A
N/A
0.6
4.3
4.90
MPC17
730
3435
CG50.4
24
47
N/A
N/A
0.7
4.0
4.70
MPC18
730
3657
CG50.4
25
72
N/A
N/A
0.7
4.9
5.60
73
Table XIVa: Power Flame #2 Oil Burner Specifications
BOILER
MODEL
BURNER BURNER
MIN.
MAX.
BURNER
INPUT
INPUT
MODEL
(GPH)
(GPH)
DIFFUSER
OPENING
(IN.)
MPC4
3.0
3.55
C1-O
3/16
MPC5
3.0
5.5
C1-O
MPC6
3.0
7.1
C1-O
MPC7
3.0
8.7
C1-O
MPC8
5.5
10.2
C2-OA
APPROX. HIGH FIRE
HIGH FIRE
DAMPER SETTING PUMP
NOZZLE
TOP / BOTTOM DAMPER PRESSURE
MAKE
(IN.)
(PSI)
NOZZLE DATA
GPH X ANGLE
- TYPE
5/16 / Closed
300
Delavan
2.5 X 90 - B
3/8
1 / Closed
300
Delavan
3.5 X 80 - B
1/4
1-3/32 / 1-3/8
270
Delavan
4.5 X 90 - B
1/4
3/4 / 3/4
270
Delavan
6.0 X 90 - B
1/4
1 / Closed
300
Monarch
6.5 X 80 - PLP
MPC9
5.5
11.8
C2-OA
1/4
13/16 / 11/16
300
Monarch
7.0 X 80 - PLP
MPC10
5.5
13.4
C2-OA
3/16
Both Wide Open
250
Monarch
8.5 X 80 - PLP
MPC11
5.5
15.0
C2-OA
3/8
1-3/8 / 1-1/4
260
Monarch
9.5 X 70 - PLP
MPC12
5.5
16.6
C2-OB
3/8
1-3/4 / 1-3/4
300
Monarch
10.5 X 70 - PLP
MPC13
5.5
18.2
C2-OB
3/8
1-1/2 / 1-1/4
300
Monarch
11.0 X 80 - PLP
MPC14
5.5
19.8
C2-OB
1/2
1-1/4 / 1-1/4
270
Monarch
12.0 X 80 - PLP
MPC15
5.5
21.5
C3-O
1/2
1-7/8 / Closed
280
Hago
14.0 X 80 - BPS
MPC16
7.4
23.0
C3-O
5/16
1-3/4 / 1-3/4
225
Hago
16.0 X 80 - BPS
MPC17
7.4
24.5
C3-O
3/8
2/2
280
Hago
15.0 X 80 - BPS
MPC18
7.4
26.0
C3-O
3/8
Both Wide Open
300
Hago
16.0 X 80 - BPS
Table XIVb: Power Flame Gas Burner Specifications
BOILER
MODEL
BURNER BURNER
MIN.
MAX.
INPUT
INPUT
(MBH)
(MBH)
BURNER
MODEL
DIFFUSER
OPENING
(IN.)
APPROX. HIGH FIRE
DAMPER SETTING TOP / BOTTOM DAMPER
(IN.)
APPROX. NAT. GAS
MANIFOLD PRESS.
AT ORIFICE TEE
(“WC)
MINIMUM
NAT. GAS
INLET PRESS.
(“WC) **
1/2 *
1.2
4.0
MPC4
300
500
JR15A-10
N/A
MPC5
300
773
JR30A-12
N/A
3/4 *
1.5
4.2
MPC6
300
995
JR30A-12
N/A
13/16 *
2.5
4.9
MPC7
600
1216
JR30A-12
N/A
1-3/32 *
3.5
5.6
MPC8
650
1438
JR50A-15
N/A
3/4 *
2.0
5.9
MPC9
650
1660
JR50A-15
N/A
Wide Open *
1.5
6.9
MPC10
650
1881
JR50A-15
N/A
3*
1.8
5.8
MPC11
650
2103
JR50A-15
N/A
2-3/8*
2.1
5.0
MPC4
300
500
C1-G-10
3/16
5/16 / Closed
1.8
4.0
MPC5
300
773
C1-G-10
3/8
1 / Closed
3.8
4.4
MPC6
300
995
C1-G-12
1/4
1-3/32 / 1-3/8
2.4
4.8
MPC7
300
1216
C1-G-12
1/4
3/4 / 3/4
3.5
5.5
MPC8
750
1438
C2-G-15
1/4
1 / Closed
1.0
6.0
MPC9
750
1660
C2-G-15
1/4
13/16 / 11/16
1.4
6.8
MPC10
750
1881
C2-G-20A
3/16
Both Wide Open
2.6
5.9
MPC11
750
2103
C2-G-20A
3/8
1-3/8 / 1-1/4
2.0
6.5
MPC12
750
2325
C2-G-20A
3/8
1-3/4 / 1-3/4
2.4
5.7
MPC13
750
2547
C2-G-20B
3/8
1-1/2 / 1-1/4
2.9
6.5
MPC14
750
2769
C2-G-20B
1/2
1-1/4 / 1-1/4
3.0
6.5
MPC15
900
2991
C3-G-20
1/2
1-7/8 / Closed
1.7
5.6
MPC16
900
3213
C3-G-20
5/16
1-3/4 / 1-3/4
2.3
6.9
MPC17
900
3435
C3-G-20
3/8
2/2
2.6
6.6
MPC18
900
3657
C3-G-20
3/8
Both Wide Open
2.5
6.8
* ON “JR” BURNERS, THIS DIMENSION IS THE GAP BETWEEN THE TWO DAMPER BLADES.
** MINIMUM INLET PRESSURE FOR STANDARD UL GAS TRAINS ONLY. CONSULT FACTORY FOR ADDITIONAL INFORMATION.
74
75
10.2
11.8
1216
1438
1660
1881
2103
2325
2547
2769
2991
3213
3435
3657
MPC7
MPC8
MPC9
MPC10
MPC11
MPC12
MPC13
MPC14
MPC15
MPC16
MPC17
MPC18
5.5
C3-GO-20
C3-GO-20
C3-GO-20
C3-GO-20
C2-GO-20B
C2-GO-20B
C2-GO-20A
C2-GO-20A
C2-GO-20A
C2-GO-15
C2-GO-15
C1-GO-12
C1-GO-12
C1-GO-10
C1-GO-10
BURNER
MODEL
3/8
3/8
5/16
1/2
1/2
3/8
3/8
3/8
3/16
1/4
1/4
1/4
1/4
3/8
3/16
DIFFUSER
OPENING
(IN.)
2.6
2.5
Both Wide Open
2.3
1.7
3.0
2.9
2.4
2.0
2.6
1.4
1.0
3.5
2.4
3.8
1.8
APPROX. NAT. GAS
MANIFOLD PRESS.
AT ORIFICE TEE
(“WC)
2/2
1-3/4 / 1-3/4
1-7/8 / Closed
1-1/4 / 1-1/4
1-1/2 / 1-1/4
1-3/4 / 1-3/4
1-3/8 / 1-1/4
Both Wide Open
13/16 / 11/16
1 / Closed
3/4 / 3/4
1-3/32 / 1-3/8
1 / Closed
5/16 / Closed
APPROX. HIGH FIRE
DAMPER SETTING TOP / BOTTOM DAMPER
(IN.)
*** MINIMUM INLET PRESSURE FOR STANDARD UL GAS TRAINS ONLY. CONSULT FACTORY FOR ADDITIONAL INFORMATION.
** MAXIMUM BURNER INPUT RATES SHOWN. FOR MINIMUM BURNER INPUT RATES, SEE SEPARATE GAS AND OIL BURNER DATA.
* SEE OIL BURNER DATA FOR NOZZLE SIZES AND PUMP PRESSURE SETTINGS.
26.0
24.5
23.0
21.5
19.8
18.2
16.6
15.0
13.4
8.7
7.1
773
995
MPC5
3.55
OIL
(GPH)
MPC6
500
GAS
(MBH)
MPC4
BOILER
MODEL
BURNER INPUT **
Table XIVc: Power Flame Combination Gas / #2 Oil Burner Specifications *
6.8
6.6
6.9
5.6
6.5
6.5
5.7
6.5
5.9
6.8
6.0
5.5
4.8
4.4
4.0
MINIMUM
NAT. GAS
INLET PRESS.
(“WC) ***
SECTION VIII - Repair Parts
Figure 55: MPC Cast Iron Section Assembly
All MPC™ Repair Parts may be obtained through your local Burnham Commercial Cast Iron Wholesale
distributor. Should you require assistance in locating a Burnham Commercial Cast Iron distributor in your
area, or have questions regarding the availability of Burnham Commercial Cast Iron products or repair
parts, please contact Burnham Commercial Cast Iron Customer Service at (888) 791-3790 or Fax (877)
501-5211.
76
77
9
10
11
12
8
8
4
4
3
5/8” Dia. x 164” Lg. Pre-cut Silicone Coated
Perimeter Rope Gasket
7
Tie Rods:
8A. 5/8” - 11 x 24-1/4” Lg.
8B. 5/8” - 11 x 31” Lg.
8C. 5/8” - 11 x 37-3/4” Lg.
8D. 5/8” - 11 x 45-1/2” Lg.
8E. 5/8” - 11 x 27” Lg.
8F. 5/8” - 11 x 34” Lg.
5/8” - 11 x 2-1/8” Coupling Hex Nut, Plated
5/8” Flat Washer, USS, Plain
5/8” x 11 Hex Nut, Plain
Tie Rod Tension Spring Assembly
2
5/8” Dia. x 86” Lg. Pre-cut Silicone Coated
Combustion Chamber Rope Gasket
6
8
1
2
1
3
3
04
MPC-R Rear Section (Machined)
MPC-C Center Section (Machined)
MPC-F Front Section (Machined)
3” Cast Iron Slip Nipple (Machined)
7” Cast Iron Slip Nipple (Machined)
Description
1
2
3
4
5
Item
No.
8
8
4
4
4
3
1
3
1
4
4
05
8
8
4
4
5
4
1
4
1
5
5
06
8
8
4
4
6
5
1
5
1
6
6
07
4
8
8
4
4
4
7
6
1
6
1
7
7
08
4
4
8
8
4
4
8
7
1
7
1
8
8
09
4
4
8
8
4
4
9
8
1
8
1
9
9
10
4
4
8
8
4
4
10
9
1
9
1
10
10
11
4
4
8
8
4
4
11
10
1
10
1
11
11
12
4
4
8
8
8
4
4
12
11
1
11
1
12
12
13
Boiler Sections / Quantity
REPAIR PARTS - CAST IRON SECTION ASSEMBLY
4
4
8
8
8
4
4
13
12
1
12
1
13
13
14
4
4
8
8
8
4
4
14
13
1
13
1
14
14
15
4
4
4
8
8
8
4
15
14
1
14
1
15
15
16
8
8
8
8
4
4
16
15
1
15
1
16
16
17
8
4
12
8
8
4
4
17
16
1
16
1
17
17
18
101753-01
101754-01
101755-01
101756-01
80861022
80861083
80860455
80860608
80860460
101701-01
101635-03
101635-01
100658-01
100657-01
100656-01
7066002
7066004
Part No.
78
Figure 56: MPC Common Bare Boiler Components
79
16A
17
18
19
16
10
11
12
13
14
15
9
8A
8
4
5
6
7
3
1
2
Item
No.
1
2
1
1
19B. Sight Glass Fiber Gasket (RCF)
19C. Pyrex Sight Glass
19D. 2” Conduit Bushing Observation Port Cap, Plated
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
04
1
1
19A. 2” NPT x 2-1/2” Lg. Observation Port Nipple
5/16” Flat Washer, USS, Plated
5/16” -18 x 7/8” Lg. Hex Head Cap Screw, Plated
BSD Hinge/Latch (Machined)
BSD Hinge Loop (Machined)
7/16” Split-Lock Washer, Plated
7/16” -14 x 1-1/2” Lg. Hex Head Cap Screw, Plated
Burner Swing Door Assembly
(Includes Items 16A, 17 & 18)
Burner Swing Door, Machined & Painted
Burner Swing Door Insulation (RCF)
Internal BSD Observation Port Gasket (RCF)
Observation Port Components:
1/2” Dia. x 24-1/2” Lg. Pre-Cut Silicone Coated Rope
Gasket, (Clean-out Cover)
4” NPT CI Supply Manifold
4” NPT CI Return Manifold
5/8” x 158” Lg. Pre-Cut Silicone Coated Rope Gasket
(BSD & Flue Collector)
Cast Iron Rear Flue Collector, Machined
3/8” Flat Washer, USS, Plated
3/8” -16 x 1-1/4” Lg. Hex Head Cap Screw, Plain
1/4” NPT Square Head Plug, Pipe, Brass
Cast Iron Clean-out Cover Assembly
(Includes Items 8A & 9)
Cast Iron Clean-out Cover, Painted
Description
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
05
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
06
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
07
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
08
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
09
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
10
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
11
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
12
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
13
1
1
Boiler Sections / Quantity
REPAIR PARTS - COMMON BARE BOILER COMPONENTS
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
14
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
15
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
16
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
17
1
1
1
1
2
1
1
1
1
1
4
4
4
2
10
10
2
2
2
1
6
6
1
1
18
1
1
806600518
8026082
8026083
8066000101
102647-01
100691-01
101518-01
100688-01
80860611
80861371
100731-01
100732-01
101758-01
101759-01
101634-01
101899-01
101667-01
100743-01
80860618
80861309
806603542
101635-02
706MPC401
706MPC402
Part No.
80
Figure 56: MPC Common Bare Boiler Components (continued)
81
30
31
32
33
23
24
25
26
27
28
29
20
20A
21
22
22K. Power Flame (“JR”) BAP No. “45”, 6-3/8” Dia. Hole
22L. Power Flame (“JR”) BAP No. “41”, 9” Dia. Hole
Burner Adapter Plate Gasket (RCF)
3/8” Split-Lock Washer, Plated
3/8” -16 x 7/8” Lg. Hex Head Cap Screw, Plated
1/2” Flat Washer (USS), Plated
1/2”-13 Hex Nut, Plated
3” NPT Countersunk Pipe Plug, Black
Flue Outlet Damper Assembly, 7”
Flue Outlet Damper Assembly, 8”
Flue Outlet Damper Assembly, 10”
Flue Outlet Damper Assembly, 12”
Flue Outlet Damper Mounting Gasket
Hex Head Cap Screw 5/16 - 18 x 7/8” Plated
Washer, Flat, 1/4” USS, Plated
4” NPT x 8” Lg - Supply/Return
Gas Burner
Oil, Gas, Gas/Oil Combo Burner
22H. Power Flame (“C”) BAP No. “40”, 7-1/2” Dia. Hole
22 I. Power Flame (“C”) BAP No. “41”, 9” Dia. Hole
22J. Power Flame (“C”) BAP No. “42”, 10-3/8” Dia. Hole
- OR -
- OR -
9/16” Split-Lock Washer, Plated
5/8” Flat Washer
9/16” -12 x 2” Lg. Hex Head Cap Screw, Plated
Burner Adapter Plate Cartons (Includes Item 23):
Oil Burner
22A. Beckett (“CF”) BAP No. “00”, 6-3/4” Dia. Hole
22B. Beckett (“CF”) BAP No. “01”, 8-1/4” Dia. Hole
22C. Beckett (“CF”) BAP No. “02”, 10-1/4” Dia. Hole
Gas Burner
22D. Beckett (“CG”) BAP No. “03”, 5” Dia. Hole
22E. Beckett (“CG”) BAP No. “04”, 6” Dia. Hole
22F. Beckett (“CG”) BAP No. “07”, 7-1/4” Dia. Hole
22G. Beckett (“CG”) BAP No. “08”, 8-1/8”” Dia. Hole
Item
Description
No.
1
1
1
12
12
2
1
4
4
4
4
1
1
1
1
12
12
2
1
4
4
4
4
1
1
1
1
1
1
1
4
4
4
05
4
4
4
04
1
12
12
2
1
1
1
12
12
2
1
4
4
4
4
1
1
1
1
1
4
4
4
07
1
4
4
4
4
1
1
1
1
1
4
4
4
06
1
12
12
2
1
1
1
4
4
4
4
1
1
1
1
4
4
4
1
12
12
2
1
1
1
4
4
4
4
1
1
1
1
4
4
4
1
12
12
2
1
1
1
4
4
4
4
1
1
1
1
4
4
4
1
12
12
2
1
1
1
4
4
4
4
1
1
1
1
4
4
4
1
1
12
12
2
1
4
4
4
4
1
1
1
1
4
4
4
1
1
12
12
2
1
4
4
4
4
1
1
1
1
4
4
4
1
1
12
12
2
1
4
4
4
4
1
1
1
1
4
4
4
Boiler Sections / Quantity
08 09 10 11 12 13 14
REPAIR PARTS - COMMON BARE BOILER COMPONENTS (continued)
1
1
12
12
2
1
4
4
4
4
1
1
1
1
4
4
4
15
1
1
12
12
2
1
4
4
4
4
1
1
1
1
4
4
4
16
1
1
12
12
2
1
4
4
4
4
1
1
1
1
4
4
4
17
1
1
12
12
2
1
4
4
4
4
1
1
1
1
4
4
4
18
602263451
602263411
8022601
80860650
80861352
80860641
80860471
806603509
102471-01
102471-02
102471-03
102471-04
102472-01
80861371
80860803
806600603
602263401
602263411
602263421
602263031
602263041
602263071
602263081
602263001
602263011
602263021
101760-01
80860608
101761-01
Part No.
82
Figure 57: MPC Front & Center Section Frame Rail Assembly
83
4
5
6
7
8
9
10
11
12
3
1
2
Jacket Frame-Horizontal Support Channel
Jacket Frame-Horizontal Support Channel Bracket
#8 x 1/2” Lg. Type AB, Slotted Hex Washer Head
Sheet Metal Screw, Steel, Plated
3/8” -16 x 3-1/2” Lg. Threaded Rod
11/16” OD x 7/16” ID x 17/32” Lg. Spacer
3/8” Flat Washer, USS, Plated
3/8” -16 Serrated Flange Hex Nut, Steel, Plated
Jacket Frame-Lower Front/Center Bracket
5/8” -11 x 2” Lg. Hex Head Bolt, Plain
5/8” Flat Washer, USS, Plain
5/8” -11 Hex Nut, Plain
Jacket Frame-Vertical Side Channel (Painted)
Item
Description
No.
2
4
8
4
2
2
4
2
2
12
12
2
4
8
4
2
2
4
2
2
1
2
05
1
2
04
2
4
8
4
2
2
4
2
2
12
1
2
06
4
8
16
8
4
4
8
4
4
24
2
4
07
4
8
16
8
4
4
8
4
4
24
2
4
08
4
8
16
8
4
4
8
4
4
24
2
4
09
4
8
16
8
4
4
8
4
4
24
2
4
10
4
8
16
8
4
4
8
4
4
24
2
4
11
6
12
24
12
6
6
12
6
6
36
3
6
12
6
12
24
12
6
6
12
6
6
36
3
6
13
Boiler Sections / Quantity
REPAIR PARTS - FRONT & CENTER SECTION FRAME RAIL ASSEMBLY
6
12
24
12
6
6
12
6
6
36
3
6
14
6
12
24
12
6
6
12
6
6
36
3
6
15
6
12
24
12
6
6
12
6
6
36
3
6
16
8
20
32
16
8
8
16
8
8
48
4
8
17
8
20
32
16
8
8
16
8
8
48
4
8
18
101596-01
101597-01
80860618
80860498
100760-01
80860887
80860608
80860460
100759-01
80860018
100758-01
100757-01
Part No.
84
Figure 58: MPC Rear Section Frame Rail Assembly
85
4
5
6
7
8
9
10
11
12
13
3
1
2
Jacket Frame-Horizontal Support Channel
Jacket Frame-Horizontal Support Channel Bracket
#8 x 1/2” Lg. Type AB, Slotted Hex Washer Head
Sheet Metal Screw, Steel, Plated
3/8” -16 x 13-3/4” Lg. Threaded Rod
11/16” OD x 7/16” ID x 2-21/32” Lg. Spacer
11/16” OD x 7/16” ID x 1-23/32” Lg. Spacer
3/8” Flat Washer, USS, Plated
3/8” -16 Serrated Flange Hex Nut, Steel, Plated
Jacket Frame-Lower Rear Bracket
5/8” -11 x 2” Lg. Hex Head Bolt, Plain
5/8” Flat Washer, USS, Plain
5/8” -11 Hex Nut, Plain
Jacket Frame-Vertical Side Channel (Painted)
Item
Description
No.
2
2
2
8
4
2
2
4
2
2
12
1
2
04
2
2
2
8
4
2
2
4
2
2
12
1
2
05
2
2
2
8
4
2
2
4
2
2
12
1
2
06
2
2
2
8
4
2
2
4
2
2
12
1
2
07
2
2
2
8
4
2
2
4
2
2
12
1
2
08
2
2
2
8
4
2
2
4
2
2
12
1
2
09
2
2
2
8
4
2
2
4
2
2
12
1
2
10
2
2
2
8
4
2
2
4
2
2
12
1
2
11
2
2
2
8
4
2
2
4
2
2
12
1
2
12
2
2
2
8
4
2
2
4
2
2
12
1
2
13
Boiler Sections / Quantity
REPAIR PARTS - REAR SECTION FRAME RAIL ASSEMBLY
2
2
2
8
4
2
2
4
2
2
12
1
2
14
2
2
2
8
4
2
2
4
2
2
12
1
2
15
2
2
2
8
4
2
2
4
2
2
12
1
2
16
2
2
2
8
4
2
2
4
2
2
12
1
2
17
2
2
2
8
4
2
2
4
2
2
12
1
2
18
101596-02
101597-03
101597-02
80860618
80860498
100761-01
80860887
80860608
80860460
100759-01
80860018
100758-01
100757-01
Part No.
86
Figure 59: MPC Return Water Mixing Tube RC Assembly
87
1
1
2
MPC9
MPC10
MPC11
1
2
3
2
2
MPC14
MPC15
MPC16
MPC17
MPC18
3
3
3
3
1
1
MPC13
1
MPC12
2
1
1
1
MPC8
1
MPC7
1
1
1
MPC5
MPC6
102790-01
(18)
1
102789-01
(17-13/16)
1
1
1
1
1
100727-01
(21-5/16)
2
2
2
1
100727-02
(28-1/16)
Return Water Mixing Tube Assembly, Flared Collar
MPC4
Boiler
Model
1
1
1
1
1
1
102788-03
(18-3/4)
1
1
1
1
102788-01
(22-1/8)
1
1
1
1
1
102788-02
(28-3/4)
Return Water Mixing Tube Assembly, Square End
REPAIR PARTS - RETURN WATER MIXING TUBE RC ASSEMBLY
7
7
7
6
5
4
4
5
4
4
3
3
3
2
2
Total Tubes
Required
88
Figure 60: MPC Heat Exchanger Insulation Wrapper
89
4
3
2
1
Complete Heat Exchanger Wrapper Insulation
1A. 4” Thk Nominal x 32-5/8” x 140-3/4” Lg.
1B. 4” Thk Nominal x 39-3/8” x 140-3/4” Lg.
1C. 4” Thk Nominal x 46-1/8” x 140-3/4” Lg.
Front Heat Exchanger Wrapper Insulation
2A. 4” Thk Nominal x 24-5/8” x 140-3/4” Lg.
2B. 4” Thk Nominal x 31-3/8” x 140-3/4” Lg.
2C. 4” Thk Nominal x 38-1/8” x 140-3/4” Lg.
Center Heat Exchanger Wrapper Insulation
3A. 4” Thk Nominal x 27” x 140-3/4” Lg.
3B. 4” Thk Nominal x 33-3/4” x 140-3/4” Lg.
Rear Heat Exchanger Wrapper Insulation
4A. 4” Thk Nominal x 28-1/4” x 140-3/4” Lg.
4B. 4” Thk Nominal x 35” x 140-3/4” Lg.
4C. 4” Thk Nominal x 41-3/4” x 140-3/4” Lg.
Item
Description
No.
1
04
1
05
1
06
1
1
07
1
1
08
1
1
09
1
1
10
1
1
11
1
1
1
12
1
1
1
13
Boiler Sections / Quantity
REPAIR PARTS - Heat Exchanger Insulation Wrapper
1
1
1
14
1
1
1
15
1
1
1
16
1
2
1
17
1
1
1
1
18
101850-01
101850-02
101850-03
101851-01
101851-02
101849-01
101849-02
101849-03
101835-04
101835-05
101835-06
Part No.
90
Figure 61: MPC Internal Wiring Harness Components
91
6
2
Nylon Cable Tie, Black, T&B #TY-525M or Equivalent
5/8” Dia. Cable Clamp, Black, Heyco #3380 or
Equivalent
9
10
1
Internal Wiring Harness Assembly:
8A. MPC4 Thru MPC8
8B. MPC9 Thru MPC13
8C. MPC14 Thru MPC18
8
2
6
1
1
2
6
1
1
2
9
1
1
2
9
1
1
2
9
1
1
2
9
1
1
1
7/64” Push On Plastic Edge Trim, Polyethylene, Blk,
(Cut Length = 16” Lg.)
6
7
6
1
1
8
1
1
10
6
6
1
1
8
1
1
09
4
1
1
8
1
1
08
#8 x 2-1/2” Lg. Type AB Slotted Hex Hd Washer
Screw, SM, Steel, Plated
4
1
1
8
1
1
07
6
4
1
6
1
1
06
1
1
6
1
1
05
2
9
1
1
6
1
1
8
1
1
11
2
12
1
1
8
2
1
10
1
1
12
2
12
1
1
8
2
1
10
1
1
13
Boiler Sections / Quantity
5C. 33-13/16” Lg.
5
Main Chase-way Channel:
4A. 27-9/16” Lg.
4B. 34-5/16” Lg.
4C. 41-1/16” Lg.
Chase-way Channel Extension:
5A. 20-5/16” Lg.
5B. 27-1/16” Lg.
6
#8 x 1/2” Lg. Type AB Slotted Hex Hd Washer Sheet
Metal Screw, Plated
3
4
1
Secondary Internal J-Box Assy. w/Securing Channel
2
1
Primary Internal J-Box
04
1
Item
Description
No.
REPAIR PARTS - INTERNAL WIRING HARNESS COMPONENTS
2
12
1
1
8
1
1
1
10
1
1
14
2
12
1
1
8
2
1
10
1
1
15
2
12
1
1
8
2
1
10
1
1
16
2
15
1
1
10
3
1
12
1
1
17
2
15
1
1
10
1
2
1
12
1
1
18
8136077
8136050
101438-01
101438-02
101438-03
101846-01
101757-01
101519-03
101519-01
101519-02
101432-01
101432-02
101432-03
80860018
101533-01
101418-01
Part No.
92
Figure 62: MPC Jacket Panel Assembly
93
10
9
8
7
38
2
1
05
38
2
1
06
1
1
1
Jacket Left Rear Panel Assy. w/ Insulation
1
1
1
Jacket Right Rear Panel Assy. w/ Insulation
1
1
1
Jacket Blank Sensor J-Box Cover
Jacket Outer Top Corner Panel Assembly with Short & Long Brackets:
2
6A. 27” Lg.
2
6B. 33-3/4” Lg.
2
6C. 40-1/2” Lg.
Jacket Outer Top Intermediate Panel Assembly with Long Brackets:
7A. 27-1/16” Lg.
7B. 33-13/16” Lg.
Jacket Outer Top Corner Panel Assembly with Short Brackets:
2
2
2
8A. 6-11/116” Lg.
8B. 27” Lg.
8C. 33-3/4” Lg.
8D. 40-1/2” Lg.
Jacket Front Top Panels:
1
9A. 22-5/16” Lg.
1
9B. 29-1/16” Lg.
1
9C. 35-13/16” Lg.
Jacket Intermediate Top Panels:
10A. 20-5/16” Lg.
10B. 27-1/16” Lg.
10C. 33-13/16” Lg.
38
#8 x 2-1/2” Lg. Type AB, Slotted Hex Washer Head
Sheet Metal Screw, Steel, Plated
3
4A
4B
5
6
2
Jacket Front Panel Wiring Harness Cover Plate
2
1
04
Jacket Front Panel
Description
1
Item
No.
1
1
1
1
2
1
1
2
2
1
1
2
1
46
2
1
08
1
46
2
1
07
1
1
2
2
1
1
1
46
2
1
09
1
1
2
2
1
1
1
46
2
1
10
1
1
2
2
1
1
1
46
2
1
11
1
1
1
2
2
2
1
1
1
58
2
1
12
2
1
2
2
2
1
1
1
58
2
1
13
Boiler Sections / Quantity
REPAIR PARTS - JACKET PANEL ASSEMBLY
2
1
2
2
2
1
1
1
58
2
1
14
2
1
2
2
2
1
1
1
58
2
1
15
2
1
2
2
2
1
1
1
58
2
1
16
3
1
2
4
2
1
1
1
70
2
1
17
3
1
2
2
2
2
1
1
1
70
2
1
18
100737-03
100737-02
100737-01
100736-03
100736-02
100736-01
100763-04
100763-03
100763-02
100763-01
100764-02
100764-01
100765-03
100765-02
100765-01
101427-01
101708-01
101709-01
80860018
101422-01
100753-01
Part No.
94
Figure 62: MPC Jacket Panel Assembly (continued)
95
17
18A
18B
19
16
15
11
12
13
14
Jacket Rear Top Panel
Internal J-Box Cover Plate
7/8” Dia. Black Snap-in Plug, Alliance #S-78
Jacket Side Panel Assemblies with Labels:
14A. 19-7/16” x 55-5/16”
14B. 23-3/16” x 55-5/16”
14C. 26-3/16” x 55-5/16”
14D. 29-15/16/” x 55-5/16”
14E. 32-15/16” x 55-5/16”
14F. 36-11/16” x 55-5/16”
Jacket Side Panels:
15A. 19-7/16” x 55-5/16”
15B. 23-3/16” x 55-5/16”
15C. 26-3/16” x 55-5/16”
15D. 29-15/16” x 55-5/16”
15E. 32-15/16” x 55-5/16”
15F. 36-11/16” x 55-5/16”
Snap-Bushing, Heyco SB-1093-15, #2166,
Black
MPC Logo Name Plate
Jacket Left Front BSD Cover Panel Assy.
Jacket Right Front BSD Cover Panel Assy.
Jacket BSD Cover Hanger Bracket
Item
Description
No.
1
1
1
1
4
1
1
1
2
8
04
1
1
1
1
4
1
1
1
2
8
05
1
1
1
1
4
1
1
1
2
8
06
1
1
1
1
8
1
2
1
1
2
8
07
1
1
1
1
8
2
1
1
1
2
8
08
1
1
1
1
8
1
2
1
1
2
8
09
1
1
1
1
8
2
1
1
1
2
8
10
1
1
1
1
8
1
2
1
1
2
8
11
1
1
1
1
12
2
3
1
1
2
8
12
1
1
1
1
12
3
2
1
1
2
8
13
Boiler Sections / Quantity
REPAIR PARTS - JACKET PANEL ASSEMBLY (continued)
1
1
1
1
12
1
2
2
1
1
2
8
14
1
1
1
1
12
2
3
1
1
2
8
15
1
1
1
1
12
3
2
1
1
2
8
16
1
1
1
1
16
5
2
1
1
2
8
17
1
1
1
1
16
3
2
2
1
1
2
8
18
101640-01
100748-01
100749-01
100750-01
8136257
100746-01
100746-02
100746-03
100746-04
100746-05
100746-06
101767-06
101767-01
101767-02
101767-03
101767-04
101767-05
100735-01
101190-01
100091-01
Part No.
96
Figure 63: MPC 2nd and 3rd Pass Flueway Baffles
97
2
1
2nd Pass Flueway Baffles, 304 Stainless Steel:
1A. 18” 2P Baffle Assembly w/Handles
1B. 24¾” 2P Baffle Assembly w/Handles
1C. 31½” 2P Baffle Assembly w/Handles
1D. 38¼” 2P Baffle Assembly w/Handles
1E. 45” 2P Baffle Assembly w/Handles
1F. 51¾” 2P Baffle Assembly w/Handles
1G. 58½” 2P Baffle Assembly w/Handles
1H. 65¼” 2P Baffle Assembly w/Handles
1J. 72” 2P Baffle Assembly w/Handles
1K. 78¾” 2P Baffle Assembly w/Handles
3rd Pass Flueway Baffle Assembly w/Handles,
25-1/4” Lg., Cold Rolled Steel
Item
Description
No.
4
4
04
4
4
05
4
4
06
4
4
07
4
4
08
4
4
09
4
4
10
4
4
11
4
12
4
13
Boiler Sections / Quantity
REPAIR PARTS - MPC 2ND AND 3RD PASS FLUEWAY BAFFLES
4
14
4
15
4
16
4
17
4
18
101652-01
101647-01
101647-02
101647-03
101647-04
101647-05
101647-06
101647-07
101647-08
101647-09
101647-10
Part No.
98
Figure 64: MPC Standard 50 PSI Trim & Control with 30 PSI and 80 PSI Working Pressure Trim Options
99
1
Temperature/Pressure Gauge, 3¼” Dia., ½” NPT,
0-100 PSI
Relief Valve, 50 PSI:
40
50
80
70
60
1
Wiring Harness, Operating Control
30
80C. 1½” x 1¼”
80B. 1½” x 1“
80A. 1½” x ¾”
Reducing Bushing, Black Malleable:
70C. 1¼” x 4” Lg.
70B. 1” x 4” Lg.
70A. ¾” x 3½” Lg.
Nipple, SCH.40, Black:
60C. 1¼” x 90°
60B. 1” x 90°
60A. ¾” x 90°
Street Elbow, Black Malleable:
50C. Conbraco #10-616-10, 1¼” x 1½”
50B. Conbraco #10-615-10, 1” x 1¼”
1
1
1
1
1
Immersion Well, Honeywell 123871A, ¾” x 3”
Insulation
20
50A. Conbraco #10-614-10, ¾” x 1”
1
04
Operating Control, Honeywell L4006A2015
Description
10
Item
No.
1
1
1
1
1
1
1
1
05
1
1
1
1
1
1
1
1
06
1
1
1
1
1
1
1
1
07
1
1
1
1
1
1
1
1
08
1
1
1
1
1
1
1
1
09
1
1
1
1
1
1
1
1
10
1
1
1
1
1
1
1
1
11
1
1
1
1
1
1
1
1
12
1
1
1
1
1
1
1
1
13
Boiler Sections / Quantity
1
1
1
1
1
1
1
1
14
1
1
1
1
1
1
1
1
15
1
1
1
1
1
1
1
1
16
REPAIR PARTS - STANDARD WATER TRIM & CONTROL AND OPTIONAL WORKING PRESSURE TRIM
1
1
1
1
1
1
1
1
17
1
1
1
1
1
1
1
1
18
806600539
806600521
806600507
806600028
806600026
806600038
806601516
806601514
806601501
81660357
81660362
81660359
8056028
101385-01
80160452
80160400
Part No.
100
Figure 64: MPC Standard 50 PSI Trim and Control with 30 PSI and 80 PSI Working Pressure Trim Options (continued)
101
Description
OPTIONAL WORKING PRESSURE TRIM:
51 Relief Valve, 30 PSI:
51A. Conbraco #10-614-05, ¾” x 1”
51B. Conbraco #10-615-05, 1” x 1¼”
51C. Conbraco #10-616-05, 1¼” x 1½”
51D. Conbraco #10-617-05, 1½ x 2”
61 Street Elbow, Black Malleable:
61A. ¾” x 90°
61B. 1” x 90°
61C. 1¼” x 90°
61D. 1½” x 90°
71 Nipple, SCH.40, Black
71A. ¾” x 3½” Lg.
71B. 1” x 4“ Lg.
71C. 1¼” x 4” Lg.
71D. 1½” x 4½” Lg.
81 Reducing Bushing, Black Malleable:
81A. 1½” x ¾”
81B. 1½” x 1”
81C. 1½” x 1¼”
52 Relief Valve, 80 PSI:
52A. Conbraco #10-614-16, ¾” x 1”
52B. Conbraco #10-615-16, 1” x 1¼”
62 Street Elbow, Black Malleable:
62A. ¾” x 90°
62B. 1” x 90°
72 Nipple, SCH.40, Black:
72A. ¾” x 3½” Lg.
72B. 1” x 4” Lg.
82 Reducing Bushing, Black Malleable:
82A. 1½” x ¾”
82B. 1½” x 1”
Item
No.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
05
1
04
1
1
1
1
1
1
1
1
06
1
1
1
1
1
1
1
1
07
1
1
1
1
1
1
1
1
08
1
1
1
1
1
1
1
1
09
1
1
1
1
1
1
1
1
10
1
1
1
1
1
1
1
1
11
1
1
1
1
1
1
1
1
12
1
1
1
1
1
1
1
1
13
Boiler Sections / Quantity
1
1
1
1
1
1
1
1
14
1
1
1
1
1
1
1
1
15
1
1
1
1
1
1
1
1
16
1
1
1
1
1
1
1
17
1
1
1
1
1
1
1
18
81660337
81660338
81660334
81660335
Part No.
806600507
806600521
806600038
806600026
806601501
806601514
81660365
81660366
806600507
806600521
806600539
806600038
806600026
806600028
806600016
806601501
806601514
806601516
806601517
REPAIR PARTS - STANDARD WATER TRIM & CONTROL AND OPTIONAL WORKING PRESSURE TRIM (continued)
102
Figure 65: MPC Optional Controls
103
5
4
3
2
1
Item
No.
1
1
1
2B. Immersion Well, Honeywell 123871A, ¾” NPT x 3” Insulation
2C. Wiring Harness, High Limit to J-Box
1
1
3B. Immersion Well, Honeywell 123872A, ½” NPT x 3” Insulation
3C. Wiring Harness, LFH Control to J-Box
1
1
4B. Immersion Well, Honeywell 123871A, ¾” NPT x 3” Insulation
4C. Wiring Harness, LHL Control to J-Box
1
1
1
5A. Honeywell T991A1061
5B. Immersion Well, Honeywell 112630AA, ¾” NPT x 1” Insulation
5C. Wiring Harness, Mod. Control to J-Box
Modulation Control:
1
4A. Limit, Honeywell L4006A2015
Low / High / Low Control:
1
3A. Limit, Honeywell L4006B1189
Low Fire Hold Control:
1
2A. Limit, Honeywell L4006E1133
Limit, High Limit Control:
1
1B. Wiring Harness, LWCO to J-Box
04
1A. LWCO, McDonnell & Miller 750 P-MT-120 w/Probe
Probe Low Water Cut-Off:
Description
1
1
1
1
1
1
1
1
1
1
1
1
1
1
05
1
1
1
1
1
1
1
1
1
1
1
1
1
1
06
1
1
1
1
1
1
1
1
1
1
1
1
1
1
07
1
1
1
1
1
1
1
1
1
1
1
1
1
1
08
1
1
1
1
1
1
1
1
1
1
1
1
1
1
09
1
1
1
1
1
1
1
1
1
1
1
1
1
1
10
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11
1
1
1
1
1
1
1
1
1
1
1
1
1
1
12
1
1
1
1
1
1
1
1
1
1
1
1
1
1
13
Boiler Sections / Quantity
REPAIR PARTS - COMMON OPTIONAL CONTROLS
1
1
1
1
1
1
1
1
1
1
1
1
1
1
14
1
1
1
1
1
1
1
1
1
1
1
1
1
1
15
1
1
1
1
1
1
1
1
1
1
1
1
1
1
16
1
1
1
1
1
1
1
1
1
1
1
1
1
1
17
1
1
1
1
1
1
1
1
1
1
1
1
1
1
18
101387-01
80160459
80160458
101389-01
80160452
80160400
101386-01
80160497
80160656
101388-01
80160452
80160703
101398-01
80160718
Part No.
Appendix A - Figures
Figure Number
Page Number
Description
Equipment Check List
Figure 1a
2
Carton Identification
Section I - General Information
Figure 1b
10
Dimensional Information
Figure 2
14
Boiler Foundation
Figure 3a
15
MPC With Rear Outlet Vent
Figure 3b
16
Vents - Faults and Suggestions
Section II - Cast Iron Block Assembly Instructions (Knockdown Boilers)
Figure 4a
17
Lifting Instructions - Limited to 4 thru 12 Section Block Assembly
(No Steel Base)
Figure 4b
17
Lifting Instructions - 4 thru 18 Section Block Assembly w/Steel Base
Figure 5
19
Manual or Hydraulic Draw-up Section Assembly
Figure 6
20
Vertical Bracing of Rear Section
Figure 7
20
Setting of Nipples
Figure 8
20
Inspection Pad Locations for Section Draw-up
Section III - Boiler Assembly Instructions (Knockdown Boiler)
104
Figure 9
25
Installation of Common Parts to Block Assembly
Figure 10
26
Universal Hinge/Latch Casting
Figure 11
26
Hinge Loop
Figure 12
27
Orientation of Supply Manifold
Figure 13
29
Return Water Mixing Tube Reduced Clearance Assembly and Installation
Figure 14
30
Orientation of Return Manifold
Figure 15
30
Hand Form Support Channel Bracket
Figure 16
31
Secure Bracket to Horizontal Channel
Figure 17a
32
Front/Center Section Horizontal Channel Assembly w/Mounting Hardware
Figure 17b
32
Rear Section Horizontal Channel Assembly w/Mounting Hardware
Figure 18a
33
Mount Rear Section Horizontal Channel to Block Assembly
Figure 18b
33
Mount Rear Section Horizontal Channel to Block Assembly
Figure 19
34
Attachment of Lower Front/Center Section Bracket to Casting Leg
Figure 20
34
Attachment of Lower Rear Section Bracket to Casting Leg
Figure 21
35
Securing Frame Side Channels to Horizontal Top Channel and Lower
Brackets
Figure 22
36
Lower tie Bar Installation
Figure 23
37
Heat Exchanger Insulation - One Piece and Modular Wrappers
Figure 24a
38
Internal Wiring Harness Components
Figure 24b
38
Internal Wiring Harness Components - Mounting Junction Boxes
Figure 24c
39
Internal Wiring Harness Components - Install Main Chaseway Channel
Figure 24d
39
Internal Wiring Harness Components - Install Chaseway Channel
Extension(s)
Figure 24e
40
Internal Wiring Harness Components - Install Protective Edging
Figure 24f
40
Internal Wiring Harness Components - Install and Secure Harness to
Chaseway
Figure 24g
41
Internal Wiring Harness Components - Secure Harness to Vertical
Channel
Appendix A - Figures (continued)
Figure Number
Page Number
Description
Section III - Boiler Assembly Instructions (Knockdown Boiler) (continued)
Figure 25
42
Internal Wiring Harness - Length Adjustment for Penetration Through Side
of Jacket Front Panel
Figure 26
44
Install Top Corner/Intermediate Panels
Figure 27
44
Install Jacket Front Panel
Figure 28
45
Jacket Split Rear Panel Detail
Figure 29
45
Install Jacket Split Rear Panel
Figure 30a
46
Installing Jacket Top Panels - Viewed From Front
Figure 30b
47
Install Jacket Top Panels - Viewed From Rear
Figure 30c
47
Install Jacket Rear Top Panel - Viewed Front Rear
Figure 31
47
Install Burner Swing Door
Figure 32
49
Install 3rd Pass Flueway Baffles (4 thru 11 Section Boilers Only)
Figure 33
49
Install 2nd Pass Flueway Baffles
Figure 34
50
Secure Burner Swing Door for Tight Perimeter Seal
Figure 35
50
Install Burner Adapter Plate and Burner to Burner Swing Door
Figure 36
51
Burner Adapter Plate Options
Figure 37
52
Install Jacket Front Panel Harness Cover Plates and Logo Plate
Figure 38
52
Purpose of tappings in Supply Manifold
Figure 39
53
Install Standard Trim and Operating Control
Figure 40
53
Control Connections to Internal Wiring Harness
Figure 41
54
Install Probe Low Water Cut-Off
Figure 42
54
Install High Limit Control
Figure 43
55
Install Modulation Control
Figure 44
55
Install Low/High/Low Control
Figure 45
55
Install Modulation Control
Figure 46
56
Install Flue Outlet Damper Assembly
Figure 47
57
Install Jacket Panels for Optional Burner Swing Door Cover
Section IV - Installation Instructions
Figure 48
58
Packaged Boiler Shipping Information
Figure 49a
59
Recommended MPC Minimum Piping - Single Boiler Application
Figure 49b
60
Recommended MPC Minimum Piping - Multiple Boiler Application
Figure 50a
61
Alternate MPC Minimum Piping - Single Boiler Application
Figure 50b
62
Alternate MPC Minimum Piping - Multiple Boiler Application
Figure 51
63
Parallel Piping Conversion
Figure 52
63
Typical Burnham Boiler - Primary-Secondary Loop System
Figure 53
63
Recommended Piping for Combination Heating & Cooling (Refrigeration)
Systems
Figure 54
64
Discharge Piping for Pressure Relief Valve
Section V - Operating Instructions
Section VI - Service Instructions
Section VII - Burner Specifications
105
Appendix A - Figures (continued)
Figure Number
Section VIII - Repair Parts
106
Page Number
Description
Figure 55
76
MPC Cast Iron Section Assembly
Description
77
Cast Iron Section Assembly
Figure 56
78
MPC Common Bare Boiler Components
Description
79
Common Bare Boiler Components
Figure 56
80
MPC Common Bare Boiler Components (continued)
Description
81
Common Bare Boiler Components
Figure 57
82
MPC Front & Center Section Frame Rail Assembly
Description
83
Front & Center Section Frame Rail Assembly
Figure 58
84
MPC Rear Section Frame Rail Assembly
Description
85
Rear Section Frame Rail Assembly
Figure 59
86
MPC Return Water Mixing Tube (RC) Assembly
Description
87
Return Water Mixing Tube (RC) Assembly
Figure 60
88
MPC Heat Exchanger Insulation Wrapper
Description
89
Heat Exchanger Insulation Wrapper
Figure 61
90
MPC Internal Wiring Harness Components
Description
91
Internal Wiring Harness Components
Figure 62
92/94
MPC Jacket Panel Assembly
Description
93/95
Jacket Panel Assembly
Figure 63
96
MPC 2nd and 3rd Pass Flueway Baffles
Description
97
MPC 2nd and 3rd Pass Flueway Baffles
Figure 64
98/100
MPC Standard 50 PSI Trim & Control with 30 PSI and
80 PSI Working Pressure Trim Options
Description
99/101
Standard Water Trim & Control and Optional Working
Pressure Trim
Figure 65
102
MPC Optional Controls
Description
103
Common Optional Controls
Appendix B - Tables
Table Number
Page Number
Section I - General Information
Description
Table I
11
Dimensional Information
Table II
12
Ratings/Data
Table III
13
Recommended Rear Service Clearance
Table IV
13
Minimum Installation Clearances to Combustible Materials
Table V
14
Boiler Foundation
Section II - Cast Iron Block Assembly Instructions (Knockdown Boiler)
Table VI
22
Proper Arrangement of Threaded Rods and Coupling Nuts
Section III - Boiler Assembly Instructions (Knockdown Boiler)
Table VII
28
Modular Return Water Mixing Tube (RWMT RC)
Table VIII
31
Frame/Bracket Mounting Locations
Table IX
41
Internal Wiring Harness Adjustment
Table X
43
Jacket Top Corner/Intermediate Panel Arrangement
Table XI
46
Jacket Top Panel Arrangement
Section IV - Installation Instructions
Section V - Operating Instructions
Section VI - Service Instructions
Table XII
71/72
Recommended Periodic Testing Check List
Section VII - Burner Specifications
Table XIIIa
73
Beckett #2 Oil Burner Specifications
Table XIIIb
73
Beckett Gas Burner Specification
Table XIVa
74
Power Flame #2 Oil Burner Specifications
Table XIVb
74
Power Flame Gas Burner Specifications
Table XIVc
75
Power Flame Combination Gas/#2 Oil Burner Specifications
107
For Commercial Grade Boilers
Limited Warranty
Using Cast Iron, Carbon Steel,
or Stainless Steel Heat Exchangers
and Parts / Accessories
Subject to the terms and conditions set forth below, Burnham Commercial, Lancaster,
Pennsylvania hereby extends the following limited warranties to the original owner of a
commercial grade water or steam boiler or Burnham Commercial supplied parts and/or
accessories manufactured and shipped on or after October 1, 2009:
ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS
AND PARTS / ACCESSORIES SUPPLIED BY BURNHAM COMMERCIAL.
Burnham Commercial warrants to the original owner that its commercial grade water
and steam boilers and parts/accessories 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 commercial grade boiler or
any part or accessory provided by Burnham Commercial is found to be defective in
material or workmanship during this one year period, Burnham Commercial will, at its
option, repair or replace the defective part (not including labor).
HEAT EXCHANGER WARRANTIES
Burnham Commercial warrants to the original owner that the heat exchanger of its
commercial grade boilers will remain free from defects in material and workmanship
under normal usage for the time period specified in the chart below to the original owner
at the original place of installation. If a claim is made under this warranty during the “No
Charge” period from the date of original installation, Burnham Commercial will, at its
option, repair or replace the heat exchanger (not including labor). If a claim is made
under this warranty after the expiration of the “No Charge” period from the date of
original installation, Burnham Commercial 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:
Service Charge as a % of Retail Price
Years in Service
1
2
3
4 5
6
7
8 9
Cast Iron
No Charge
100
Carbon Steel
No Charge
No Charge
Stainless Steel
20 40 60 80
10+
100
100
NOTE: If the heat exchanger 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 set
forth in Burnham Commercial Repair Parts Pricing where the heat exchanger last
appeared or the current retail price of the then nearest equivalent heat exchanger,
whichever is greater.
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 boilers, parts, or accessories
designated as commercial grade by Burnham Commercial and installed and
used exclusively for purposes of commercial space heating or domestic hot
water generation through a heat exchanger (or a combination for such purposes)
and do not apply to residential grade products or industrial uses.
2. Components Manufactured by Others: Upon expiration of the one year limited
warranty on commercial grade boilers, all boiler components other than heat
exchangers manufactured by others but furnished by Burnham Commercial
(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 Burnham Commercial are
conditioned upon the installation of the commercial grade boiler, parts, and
accessories in strict compliance with Burnham Commercial installation
instructions. Burnham Commercial specifically disclaims liability of any kind
caused by or relating to improper installation.
4. Proper Use and Maintenance: The warranties extended by Burnham Commercial
conditioned upon the use of the commercial grade boiler, parts, and accessories
for its intended purposes and its maintenance accordance with Burnham
Commercial recommendations and hydronics industry standards. For proper
installation, use, and maintenance, see all applicable sections of the Installation
and Operating, and Service Instructions Manual furnished with the unit.
5. This warranty does not cover the following:
a. Expenses for removal or reinstallation. The owner will be responsible for
the cost of removing and reinstalling the alleged defective part or its
replacement and all labor and material connected therewith, and
transportation to and from Burnham Commercial.
b. Components that are part of the heating system but were not furnished by
Burnham Commercial as part of the commercial boiler.
c. Improper burner adjustment, control settings, care or maintenance.
d. This warranty cannot be considered as a guarantee of workmanship of an
installer connected with the installation of the Burnham Commercial boiler, or
as imposing on Burnham Commercial liability of any nature for unsatisfactory
performance as a result of faulty workmanship in the installation, which
liability is expressly disclaimed.
Pub. No. BCL1109041
108
e. Boilers, parts, or accessories installed outside the 48 contiguous United
States, the State of Alaska and Canada.
f. Damage to the boiler and/or property due to installation or operation of the
boiler that is not in accordance with the boiler installation and operating
instruction manual.
g. Any damage or failure of the boiler resulting from hard water, scale buildup
or corrosion the heat exchanger.
h. Any damage caused by improper fuels, fuel additives or contaminated
combustion air that may cause fireside corrosion and/or clogging of the
burner or heat exchanger.
i. Any damage resulting from combustion air contaminated with particulate
which cause clogging of the burner or combustion chamber including but
not limited to sheetrock or plasterboard particles, dirt, and dust particulate.
j. Any damage, defects or malfunctions resulting from improper operation,
maintenance, misuse, abuse, accident, negligence including but not limited to
operation with insufficient water flow, improper water level, improper water
chemistry, or damage from freezing.
k. Any damage caused by water side clogging due to dirty systems or
corrosion products from the system.
l. Any damage resulting from natural disaster.
m. Damage or malfunction due to the lack of required maintenance outlined in
the Installation and Operating Manuals furnished with the unit.
6. Exclusive Remedy: Burnham Commercial obligation for any breach of these
warranties is limited to the repair or replacement of its parts (not including
labor) in accordance with the terms and conditions of these warranties.
7. Limitation of Damages: Under no circumstances shall Burnham Commercial 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.
Burnham Commercial liability under these warranties shall under no circumstances
exceed the purchase price paid by the owner for the commercial grade 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
Burnham Commercial with respect to any defect in a commercial grade boiler,
parts, or accessories and Burnham Commercial 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 COMMERCIAL GRADE BOILER SHALL
EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE
HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE
OF INSTALLATION. SOME STATES DO NOT 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 Warranty Card provided with the product or register product online
at www.burnhamcommercialcastiron.com 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 Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604, giving full
particulars in support of the claim. The owner is required to make available for
inspection by Burnham Commercial or its representative the parts claimed to be
defective and, if requested by Burnham Commercial to ship these parts prepaid
to Burnham Commercial 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.
Commercial Boilers
Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604
Revised November 1, 2009