Burnham MPC User manual
101786-01R5-11/10 Price - $5.00
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2
EQUIPMENT CHECK LIST
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 specied carton.
Some cartons use all contents immediately and others use
parts throughout the assembly procedure until depleted. Figure 1a: Carton Identication
KNOCKDOWN BOILER - EQUIPMENT CHECK LIST
Component Description
Carton
Designation
on Bar Code
Label
Part
Number
Qty. Req’d. Per Boiler Size
4 Sect.
5 Sect.
6 Sect.
7 Sect.
8 Sect.
9 Sect.
10 Sect.
11 Sect.
12 Sect.
13 Sect.
14 Sect.
15 Sect.
16 Sect.
17 Sect.
18 Sect.
Castings (Shipped Loose - Field Assembly)
MPC Common Castings & Parts Skid
(Includes Front Section, Rear Section,
Burner Swing Door Assembly,
Rear Flue Collector and
Miscellaneous Common Parts Carton)
CP-S 101829-01 1 1 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
Parts Cartons
Boiler Assembly Cartons
BAC4 101831-01 1 1 1 1
BAC5 101831-02 1 1 1 1
BAC6 101831-03 1 1 1
BAC7 101831-04 1 1 1 1
BAC4 Multi 101831-05 1 1 1 1 1 2
BAC5 Multi 101831-06 1 1 1 1 1 1 1 1 2 1
Supply & Return Manifold Carton S/RM CI 103818-01 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Return Water Mixing Tube Cartons
Restricted Clearance
RWMT 4 RC 102804-04 1
RWMT 5 RC 102804-05 1
RWMT 6 RC 102804-06 1
RWMT 7 RC 102804-07 1
RWMT 8 RC 102804-08 1
RWMT 9 RC 102804-09 1
RWMT 10 RC 102804-10 1
RWMT 11 RC 102804-11 1
RWMT 12 RC 102804-12 1
RWMT 13 RC 102804-13 1
RWMT 14 RC 102804-14 1
RWMT 15 RC 102804-15 1
RWMT 16 RC 102804-16 1
RWMT 17 RC 102804-17 1
RWMT 18 RC 102804-18 1
Jacket
Frame
Cartons
Jacket Frame (Front/Rear Rails) JF-1 101834-01 1 1 1 1 1 1 1 1
Jacket Frame
(Front/Center/Rear Rails) JF-2 101834-02 1 1 1 1 1 1 1
Jacket Frame (Center Rails) JF-3 101834-03 1 1 1 1 1 1 1
(Continued)
NOTE: Only factory packaged and retested units are eligible to bear the UL listing mark.
3
KNOCKDOWN BOILER - EQUIPMENT CHECK LIST (Continued)
Component Description
Carton
Designation
on Bar
Code Label
Part
Number
Qty. Req’d. Per Boiler Size
4 Sect.
5 Sect.
6 Sect.
7 Sect.
8 Sect.
9 Sect.
10 Sect.
11 Sect.
12 Sect.
13 Sect.
14 Sect.
15 Sect.
16 Sect.
17 Sect.
18 Sect.
Parts Cartons (Continued)
Heat Exchanger
Insulation Bags
Complete Heat Exchanger
Insulation Wrapper
CPHW 4 101835-04 1
CPHW 5 101835-05 1
CPHW 6 101835-06 1
Front Heat Exchanger
Insulation Wrapper
FTHW 1 101849-01 1
FTHW 2 101849-02 1 1 1 1 1 1 1
FTHW 3 101849-03 1 1 1 1
Rear Heat Exchanger
Insulation Wrapper
RRHW 1 101850-01 1 1 1 1
RRHW 2 101850-02 1 1 1 1 1 1
RRHW 3 101850-03 1 1
Center Heat Exchanger
Insulation Wrapper CTHW 1 101851-01 1 1 1 1
CTHW 2 101851-02 1 1 1 1 1
Jacket Panel
Cartons
(4 Cartons
Required per
Boiler)
Jacket Common Panels
(Front and Rear) JC-1 101836-01 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Jacket Uncommon Panels
(Outer Top Panels, Tie Bars,
Chaseway Channels &
Internal Wiring Harness)
JC2- 4 101837-04 1
JC2- 5 101837-05 1
JC2- 6 101837-06 1
JC2- 7 101837-07 1
JC2- 8 101837-08 1
JC2- 9 101837-09 1
JC2- 10 101837-10 1
JC2- 11 101837-11 1
JC2- 12 101837-12 1
JC2- 13 101837-13 1
JC2- 14 101837-14 1
JC2- 15 101837-15 1
JC2- 16 101837-16 1
JC2- 17 101837-17 1
JC2- 18 101837-18 1
Jacket Uncommon Top
Panels Cartons
JC3- 4 101838-04 1
JC3- 5 101838-05 1
JC3- 6 101838-06 1
JC3- 7 101838-07 1
JC3- 8 101838-08 1
JC3- 9 101838-09 1
JC3- 10 101838-10 1
JC3- 11 101838-11 1
JC3- 12 101838-12 1
JC3- 13 101838-13 1
JC3- 14 101838-14 1
JC3- 15 101838-15 1
JC3- 16 101838-16 1
JC3- 17 101838-17 1
JC3- 18 101838-18 1
(Continued)
4
KNOCKDOWN BOILER - EQUIPMENT CHECK LIST (Continued)
Component Description
Carton
Designation
on Bar
Code Label
Part
Number
Qty. Req’d. Per Boiler Size
4 Sect.
5 Sect.
6 Sect.
7 Sect.
8 Sect.
9 Sect.
10 Sect.
11 Sect.
12 Sect.
13 Sect.
14 Sect.
15 Sect.
16 Sect.
17 Sect.
18 Sect.
Parts Cartons (Continued)
(Continued)
Jacket Panel Cartons
(4 Cartons Required
per Boiler)
Jacket Uncommon Side
Panel Cartons
JC4- 4 101839-04 1
JC4- 5 101839-05 1
JC4- 6 101839-06 1
JC4- 7 101839-07 1
JC4- 8 101839-08 1
JC4- 9 101839-09 1
JC4- 10 101839-10 1
JC4- 11 101839-11 1
JC4- 12 101839-12 1
JC4- 13 101839-13 1
JC4- 14 101839-14 1
JC4- 15 101839-15 1
JC4- 16 101839-16 1
JC4- 17 101839-17 1
JC4- 18 101839-18 1
Flueway Bafe Cartons
Second Pass Flueway
Bafe Cartons
(Stainless Steel)
2FB-18 101840-01 1
2FB-24 101840-02 1
2FB-31 101840-03 1
2FB-38 101840-04 1
2FB-45 101840-05 1
2FB-51 101840-06 1
2FB-58 101840-07 1 1 1
2FB-65 101840-08 1 1
2FB- 72 101840-09 1 1
2FB- 78 101840-10 1 1
Third Pass Flueway
Bafe Carton
(Cold Rolled Steel) 3FB 101852-01 1 1 1 1 1 1 1 1
Water Trim and
Control Cartons
30 PSI Water Trim
& Control Cartons
WT30-A 101841-01 1 1 1
WT30-B 101841-02 1 1 1
WT30-C 101841-03 1 1 1 1 1 1 1
WT30-D 101841-04 1 1
50 PSI Water Trim
& Control Cartons
WT50-A 101853-01 1 1 1 1 1 1
WT50-B 101853-02 1 1 1 1
WT50-C 101853-03 1 1 1 1 1
80 PSI Water Trim
& Control Cartons WT80-A 101854-01 1 1 1 1 1 1 1 1 1
WT80-B 101854-02 1 1 1 1 1 1
Flue Outlet Damper Carton - 7” FODC7 102473-01 1 1
Flue Outlet Damper Carton - 8” FODC8 102473-02 1 1 1
Flue Outlet Damper Carton - 10” FODC10 102473-03 1 1 1
Flue Outlet Damper Carton - 12” FODC12 102473-04 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 led 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.
5
IMPORTANT INFORMATION -
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation which,
if not avoided, may result in moderate or minor
injury or property damage.
WARNING
Indicates a potentially hazardous situation which,
if not avoided, could result in death, serious injury
or substantial property damage.
NOTICE
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.
-
6
DANGER
DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other
appliance.
WARNING
Improperinstallation,adjustment,alteration,serviceormaintenancecancausepropertydamage,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,andservicemustbeperformedonlybyanexperienced,skilledandknowledgeable
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 specied 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 ooring.
Do not install boiler on carpeting. Do not operate on oors 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 combus-
tion chamber and potentially reduce boiler longevity and may result in premature boiler failure through
thermal shock.
7
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 ttings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
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
heatingseasonand should beinspectedperiodically throughout theheatingseason for anyobstructions.
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 efciency.
This boiler is supplied with controls which may cause the boiler to shut down and not re-start without
service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in
cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent
damage if the boiler is inoperative.
This boiler is designed to burn No. 2 fuel oil only. Do not use gasoline, crankcase drainings, or any oil
containing gasoline. Never burn garbage or paper in this boiler. Do not convert to any solid fuel (i.e.
wood, coal). Do not convert to any gaseous fuel (i.e. natural gas, LP). All ammable debris, rags, paper,
wood scraps, etc., should be kept clear of the boiler at all times. Keep the boiler area clean and free of
re hazards.
Always keep the oil supply valve shut off if the burner is shut down for an extended period of time.
Probe and oat 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.
8
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 Bafes...........................................................................................49
Procedure to Close and Secure Burner Swing Door .....................................................................50
Install Burner Adapter Plate and Mount Burner (Burner Specic) ...............................................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
9
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 Ofce 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 Bafes......................................................................................................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
SECTION I - GENERAL INFORMATION
Boiler
Model
Number
of
Sections
Dim. A
(Inches)
* Burner Dimension B (Inches) Minimum Flue
Bafe Installation
Clearance Dim. C
(Inches)
Vent (Flue Outlet
Damper)
Connection Size
Dim. D (Inches)
Approx. Weight of
Sections - LBS.
(Block Assy.)
Approx.
Shipping
Weight - LBS.
(KD Boiler)
Beckett Power Flame
CF CG C JR
MPC4 4 33-3/4 10-1/4 20-3/4 29-5/8 23 35 7” 1875 2370
MPC5 5 40-1/2 12-1/4 21-3/4 29-5/8 23 35 7” 2321 2821
MPC6 6 47-1/4 20-1/2 28-1/2 29-5/8 23 41 8” 2767 3272
MPC7 7 54 20-1/2 28-1/2 29-5/8 23 48 8” 3213 3733
MPC8 8 60-3/4 21 29 34-5/8 25-3/4 55 8” 3659 4194
MPC9 9 67-1/2 21 29 34-5/8 25-3/4 61 10” 4105 4655
MPC10 10 74-1/4 21 29 34-5/8 25-3/4 68 10” 4551 5116
MPC11 11 81 22-1/2 29 34-5/8 25-3/4 68 10” 4997 5577
MPC12 12 87-7/8 22-1/2 29-3/8 34-5/8 --- 82 10” 5443 6073
MPC13 13 94-5/8 22-1/2 29-3/8 34-5/8 --- 88 12” 5889 6544
MPC14 14 101-3/8 22-1/2 29-3/8 34-5/8 --- 88 12” 6335 7015
MPC15 15 108-1/8 22-1/2 29-3/8 39-1/2 --- 82 12” 6781 7486
MPC16 16 114-7/8 26-3/8 29-3/8 39-1/2 --- 75 12” 7227 7957
MPC17 17 121-5/8 26-3/8 29-3/8 39-1/2 --- 75 12” 7673 8438
MPC18 18 128-3/8 26-3/8 29-3/8 39-1/2 --- 68 12” 8119 8919
* Burner control panel conguration may change this dimension.
Table I: Dimensional Information
12
Model MPC™ Boilers
Boiler Model
Boiler Horsepower
Burner Input
Gross Output (MBH)
Net I=B=R Rating
(MBH)
Combustion
Efciency
Heating Surface
(Sq. Ft.)
Net Furnace Volume
(Cu. Ft.)
Pressure in Firebox
(Inches Wtr. Column)
Water Content
(Gallons)
Boiler Weight
w/Water (LBS.)
Vent (Flue Outlet
Damper) Dia.
(Inches)
Oil (GPH)
Oil (MBH)
Gas (MBH)
Oil - %
Gas - %
MPC4 12.7 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
(1) Sufx “N” indicates natural gas-red, sufx “P” indicates LP gas-red, “O” indicates oil-red, “C” indicates combination natural
gas/oil-red, “D” indicates combination LP gas/oil-red.
(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 ue
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
TABLE II: RATINGS/DATA
(1) (3) (2) (4)
13
SECTION I - GENERAL INFORMATION (Continued)
INSPECT SHIPMENT carefully for any signs of
damage.
1. ALL EQUIPMENT is carefully manufactured,
inspected and packed. Our responsibility ceases
upon delivery of crated Boiler to the carrier in good
condition.
2. ANY CLAIMS for damage or shortage in shipment
must be led immediately against the carrier by
the consignee. No claims for variances from,
or shortage in orders, will be allowed by the
manufacturer unless presented within thirty (30)
days after the receipt of goods.
LOCATE THE UNIT
NOTICE
Recommended clearance for service may be
reduced to minimum clearance to combustible
material. However, increased service and
maintenance difculty 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.
:
• Provide 54” service clearance for removal,
maintenance, and servicing of burner and
controls.
• Provide service clearance for removal
of bafes to perform annual cleaning of
ueways, refer to Table I, Dimension “C”.
:
• Provide a minimum service clearance from
the boiler jacket for access to boiler supply
and return piping, relief valve, drain valve,
ue collector clean-out covers, vent piping
and optional ue damper assembly. See
Table III.
Table IV: Minimum Installation Clearances To
Combustible Materials (Inches) per
ANSI/NFPA 31 (Knockdown/Non-UL
Packaged Boiler)
C
A B Chimney D E
Boiler Above Front Connector Rear Sides
MPC 6 24 18 6 6
Note: See Table III for recommended service clearance
to access rear of boiler.
:
• 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.
:
• 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.
:
• Provide a minimum clearance from the
boiler jacket of 24”.
2. FOR MINIMUM CLEARANCES to combustible
materials, See Table IV or Table V.
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.
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
14
Table V: Minimum Installation Clearances To
Combustible Materials (Inches) per
UL726 (Packaged / Firetested Boiler)
C
A B Chimney D E F
Boiler Above Front Connector Rear Sides Below
MPC 18 48 18 18 18 NC *
* NC - Noncombustible Flooring
Note: See Table III for recommended service clearance
to access rear of boiler.
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.
WARNING
All boiler builds, except boilers bearing the
UL Label, are suitable for installation on
combustible oor. Do not install boiler on
carpeting.
Floor construction should have adequate
load bearing characteristics to bear the
weight of the boiler lled with water (see
Table 1). A boiler foundation similar to the
one shown in Figure 2 is recommended if
the boiler room oor is weak or uneven or if
a water condition exists.
4. PROVIDE AIR SUPPLYAND VENTILATION to
accommodate proper combustion.
WARNING
Failure to supply adequate air to the boiler will
result in unsafe boiler operation.
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.
Figure 2: Boiler Foundation
3. PROVIDE ADEQUATE FOUNDATION for the
unit. Refer to Figure 2.
15
a. In the absence of local requirements, the
conned 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 ring 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
ue collector during burner high re 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 ue 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 ue
outlet during burner high re 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 xed damper on the ue 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 ue 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 ring.
NOTICE
When an MPC gas red 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 red or combination gas/oil red 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.
16
Figure 3b: Vents - Faults and Suggestions
WARNING
Venting Instructions are recommendations only. Consult a venting expert on the design of a specic
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 ow
of combustion gases and can result in condensation, ue gas leakage of carbon monoxide, resulting in
severe personal injury or death.
Typical Vents that are used on Forced Draft Boilers, on Low Silhouette Buildings
-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.
1. If improper vent is suspected, remove pipe at breeching and operate boiler. This will determine if excessive
down draft, blocked or restricted ue, etc. is causing the problem.
2. If using type shown in A above, be sure cap is raised sufciently above main pipe to allow ue 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 uctuations in back pressure.
WARNING
Single wall Type C vent material is not approved for MPC boiler venting. When an MPC gas red 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 red or combination gas/oil red 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).
17
FACTORYASSEMBLED SECTIONS - The
assemblage should be set in the proper location as outlined in Section I. Lifting arrangement and weights
are given in Figures 4a and 4b.
Figure 4a: Lifting Instructions - Limited to 4 thru 12 Section Block Assembly (No Steel Base)
Figure 4b: Lifting Instructions - 4 thru 18 Section Block Assembly w/Steel Base
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
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 casting damage. Spreader width should equal B (width of skid) +12”.
Adjust cable lengths to lift at approximate center of gravity per chart.
SECTION II - CAST IRON BLOCK ASSEMBLY INSTRUCTIONS
(Knockdown Boilers)
Number of
Sections
Lifting
Weight
(lbs)
Lift Locations
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
9 4105 Section 2 Rear
10 4551 Section 2 Section 9
11 4997 Section 3 Section 10
12 5443 Section 3 Section 10
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
18 143¼ 48½ 63½ 69¼ 8663
Optional Steel Shipping Base - 4 thru 12 Section Block
Standard Steel Shipping Base - 13 thru 18 Section Block
18
Then proceed to Step C of this section on Page 24,
“HYDROSTATIC TEST”.
FIELD ASSEMBLED SECTIONS - If the boiler was
ordered knockdown, to be eld assembled, follow the
assembly procedure outlined on the following pages.
1. ASSEMBLY OF SECTIONS
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):
Place the rear section in its approximate
nal position, as outlined in Section I. Stand rear
section up and brace in vertical position with a
suitable prop. See Figure 6.
Clean the rope groove around perimeter of
the rear section with a wire brush.
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
berglass rope. The combustion chamber rope is
86” long and the perimeter rope is 164” long.
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.
While the adhesive is becoming tacky, clean
the nipples ports and nipples thoroughly with a
de-greasing solvent.
Locate a 164” length of silicone coated
berglass 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
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 nger.
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.
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 ueway [(1) 7” and (1) 3”
nipple and their corresponding nipple ports - (2)
in the rear section and (2) in the next adjoining
section].
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.
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 nished face of section, when
nipple is properly driven. See Figure 7.
Apply a generous bead of RTV 6500 or RTV
736 sealant to the (4) ueway 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
20
Figure 6: Vertical Bracing of Rear Section
Figure 8: Inspection Pad Locations for
Section Draw-up
Figure 7: Setting of Nipples
This manual suits for next models
16
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