Burnham MPC User manual

101786-01R5-11/10 Price - $5.00
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Commercial Boilers
www.burnhamcommercialcastiron.com
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3050579

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 specied carton.
Some cartons use all contents immediately and others use
parts throughout the assembly procedure until depleted. Figure 1a: Carton Identication
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 Bafe Cartons
Second Pass Flueway
Bafe 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
Bafe 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.
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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 specied 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 efciency.
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 Bafes...........................................................................................49
Procedure to Close and Secure Burner Swing Door .....................................................................50
Install Burner Adapter Plate and Mount Burner (Burner Specic) ...............................................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 Ofce 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 Bafes......................................................................................................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.