Columbia MPH SERIES User manual

COLUMBIA
MULTI-PASS HORIZONTAL BOILER
MPH SERIES
INSTALLATION,
OPERATION and
MAINTENANCE MANUAL
COLUMBIA BOILER COMPANY
POTTSTOWN, PENNSYLVANIA

Table Of Contents
PARTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
SERVICE POLICY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
BOILER ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
VENTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
JACKET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
BURNER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
BOILER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FUEL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
CLEANING AND FILLING A NEW STEAM BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
OPERATING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
STARTING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
STOPPING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
BURNER START UP AND TEST INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
CONTROL DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Daily Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Weekly Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Monthly Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Semiannual Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Annual Boiler Check & Maintenance List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

MPH COLUMBIA BOILER COMPANY
1
IMPORTANT
1. Read and familiarize yourself with this installation, operation, and mainte
nance manual before installing, operating, or servicing your boiler.
2. All cover plates, enclosures, and safety devices must be installed at all
times except while performing maintenance and service.
3. Only trained service technicians should do any work on your boiler.
4. All state and local codes take precedence over any recommendations given
in this manual.
5. Columbia Boiler performed testing on the MPH boiler line using specific
makes and models of burners. Should you choose to supply your own burn-
er, please contact the burner manufacturer to confirm compatibility with the
MPH boiler design.
6. A barometric damper or draft regulator may be required on MPH installa-
tions. A draft regulating device is required on all multiple boiler installations
where the boilers utilize common breaching. One regulator is required per
boiler. Regulators can be installed in each individual boiler breach (Location
A) or in the common breach, just upstream of each connection between the
boiler breach and the common breach. (Location B) One regulator (Location
C) is not acceptable.

MPH COLUMBIA BOILER COMPANY 2
LIMITED PARTS WARRANTY
The Columbia Boiler Company (hereinafter Columbia) warrants the burner components
and controls installed on its boiler/burner units to be free from defects in material and work-
manship under normal use and service for 12 months from the date of installation or 18
months from the date of manufacture, whichever date occurs first, and is subject to warranty
approval by the manufacturer of the specific components. This warranty does not extend to
equipment subjected to misuse, neglect, accident or improper installation. Equipment which
is defective in material or workmanship and is removed within 12 months from the date of
installation will be repaired or replaced as follows:
a. Motors, fuel units, controls, and transformers should be sent for repair or replacement
to an authorized service point or distributor of the manufacturer of such component
when reasonably available in Customer’s locality.
b. Where such local service is not available with respect to the above listed components, or
where other components are involved, such defective equipment should be returned after
receiving authorization from your dealer, freight prepaid, to the Columbia Boiler Co.,
390 Old Reading Pike, Pottstown PA 19464. The use of the Columbia returned goods
form is mandatory when returning defective material.
c. Columbia is not responsible for any labor cost for the removal and replacement of
equipment.
d. Equipment which is repaired or replaced will carry a warranty equal to the unexpired
portion of the original equipment warranty.
e. If inspection by Columbia does not disclose any defect covered by this warranty, the
equipment will be repaired or replaced at the expense of the Customer, and Columbia’s
regular charges will apply.
THIS WARRANTY IS LIMITED TO THE PRECISE TERMS SET FORTH ABOVE,
AND PROVIDES EXCLUSIVE REMEDIES EXPRESSLY IN LIEU OF ALL OTHER
REMEDIES. ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PAR-
TICULAR PURPOSE OR USE,ARE EXCLUDED. IN NO EVENT WILL COLUMBIA
BOILER CO. BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAM-
AGES OF ANY NATURE. Columbia neither assumes nor authorizes any person to assume
for Columbia any other liability or obligation in connection with the sale of this equipment.
Columbia’s liability and Customer’s exclusive remedy being limited to repairs or replacement
as set forth above.
March 10, 1997

MPH COLUMBIA BOILER COMPANY
3
INTRODUCTION
Series MPH Modified Scotch Boiler
The Columbia Multi-Pass Horizontal (MPH) boiler is a modified scotch boiler
designed for hot water, and/or low pressure steam applications. The pressure vessel
is available as a welded pipe boiler or a rolled tube boiler. These units are manufac-
tured to the specifications set forth by Section IV of the ASME Boiler and Pressure
Vessel Code. Boilers are inspected and stamped for conformity to requirements of
the National Board of Boiler and Pressure Vessel Inspectors. All boilers are designed
to be fired using No. 2 fuel oil, and/or natural, manufactured, or liquid propane (LP)
gas, and are powered by standard AC electrical service.
Columbia MPH hot water and low pressure steam boilers are typically shipped
knocked down (unassembled), but are also available factory packaged. All boilers are
furnished with a burner and boiler trim (the jacket is factory installed). Boiler trim con-
sists of the operating and limit controls, pump control and/or low water cut off
(LWCO) controls, and a safety valve. Factory packaged boilers are fully assembled
and test fired.

MPH COLUMBIA BOILER COMPANY 4
SERVICE POLICY
Steam and hot water boilers are routinely serviced by the installer or another boiler
maintenance company. Occasionally the service technician may be unable to deter-
mine the cause of the problem. In this situation, the dealer or service organization
should contact the selling distributor for help.
Should the problem persist, the distributor will contact the sales representative for
assistance. Depending on the extent of the problem, the representative may request
technical assistance from the factory.
If the problem cannot be resolved by the representative, the representative or serv-
iceman should contact the Technical Service/Engineering Department at the factory.
The following information will be needed. It is essential that this information be avail-
able to assure prompt service.
Boiler Model and Size (HP) _____________________________________________
Boiler Serial Number __________________________________________________
Boiler National Board Number ___________________________________________
Date Installed _______________________________________________________
Burner Type and Model ________________________________________________
Primary Burner Control Type ____________________________________________
Installer's Name ______________________________ Phone (___)____________
Address ____________________________________________________________
Distributors Name ____________________________ Phone (___)_____________
Address ____________________________________________________________
Sales Representative __________________________ Phone (___)_____________
Address ____________________________________________________________
Specific Problem - Detailed

MPH COLUMBIA BOILER COMPANY
5
INSTALLATION
BEFORE BEGINNING INSTALLATION, CAREFULLY STUDY THESE
INSTRUCTIONS AND ALL CHARTS, DRAWINGS, AND DIAGRAMS
SHIPPED WITH THE BOILER.
Installation must follow all state and local code requirements, Fire and Underwriters regulations,
and standard plumbing practices. The electrical installation shall be in accordance with the
National Electrical Code.
Remove all boiler components from packaging and inspect prior to assembly to ensure that
damage has not occurred in shipping.
BOILER ROOM
Locate the boiler in a well lit area on a noncombustible, level floor. Make available a convenient
water supply and allow adequate drainage, including unobstructed floor drains, for flushing and
filling the boiler. Provide sufficient make-up air for combustion at all times. See section on “Com-
bustion Air” later in this manual. Power the boiler using a properly rated electrical service.
Include fused disconnects for control circuits, blower motor circuits, and feed pump circuits that
require a motor contactor or motor starter relay.
Where possible, place the boiler on a 3 inch concrete pad. Allow adequate clearance between
the boiler and any walls or obstructions to permit inspection and service on burner, boiler pip-
ing, controls, or combustion vent.
DO NOT install exhaust fans in or near the boiler room. Exhaust fans consume available make-
up air during burner operation. More importantly, when the boiler cycles off, exhaust fans pull
hot flue gases back through the burner causing burner parts to deteriorate, and possibly fail.
Maintain a positive pressure in the boiler room at all times. Refer to the combustion air section
of this manual for additional information.
Do not allow your boiler room to become a storage room.
VENTING
Locate the boiler as close as possible to the chimney or other approved exhaust vent. Attach all
flue piping to the round flue connection and make each connection secure. The flue pipe should
not be inserted beyond the inside wall of the chimney.
DO NOT REDUCE THE SIZE OF THE FLUE OUTLET OR FLUE PIPING.
Columbia Boiler recommends the use of galvanized “B” Type vent for stack connections suit-
able for temperatures to 550F. The flue pipe should be pitched upward at least 1/4" per foot of
run. Avoid the use of tees, sharp bends, and long horizontal runs. Install a draft regulator if
required. See page 4 for draft regulator installation on multiple boilers with common breaching.
All Columbia boiler models utilize a pressure fired burner and need only to be properly vented.
For situations where unusual conditions may exist, consult the factory for proper venting.

MPH COLUMBIA BOILER COMPANY 6
COLUMBIA BOILER COMPANY OF POTTSTOWN SHALL NOT BE HELD LIABLE FOR
DAMAGE TO THE BOILER CAUSED BY INCORRECT VENT CONDITIONS AND/OR
INSUFFICIENT BURNER MAKEUP AIR.
JACKET ASSEMBLY
The jacket for the MPH boiler is factory installed and should not have to be removed for instal-
lation of the boiler.
BURNER MOUNTING
If the burner is to be installed on site, first apply a gasketing material between the burner flange
and the burner mounting plate to seal the burner. Use a non-asbestos fiber rope, or a wet insu-
lating material for a gasket, as shown in Figure 2. Wet insulation is the preferred gasketing
material because it compresses into a flat gasket which conforms to and fills any and all voids.
Secure the burner in the boiler using the four bolts supplied with the burner. See the Burner Sec-
tion of this manual for proper electrical wiring, and fuel supply piping.
Note: All factory packaged boilers use a wet insulation material as a gasket.
Figure 1

MPH COLUMBIA BOILER COMPANY
7
BOILER CONNECTIONS
Drains
All Columbia Boiler MPH units have (2) 1-1/4" drains. These are located in the front and rear of
the boiler below the fire chamber. Install a pipe nipple and ball valve in a least one for use as a
drain. If a drain is not needed, plug it by using the proper size nipple and a pipe cap. DO NOT
use a pipe plug.
Low Water Cut-Offs
All Columbia boilers are supplied with at least one low water cut-off (LWCO) as standard equip-
ment. Some boiler applications may require a secondary LWCO. The standard equipment is as
follows:
Hot Water Boilers - McDonnell & Miller 750-MT-120 Probe Type Low Water Cut-Off with
Remote Sensor - Thread the Remote Sensor into the 3/4" NPT fitting located on top of the boil-
er. Mount the Control Box near the top of the side jacket panel.
Steam Boilers - McDonnell & Miller Model 157 Low Water Cut-Off/Pump Control - Install this
device into the 1" NPT welded couplings found on the top and either side of the boiler. Only two
of the three 1" NPT will be used. The 157 can be piped to either side of the boiler.
Secondary Low Water Cut-Offs
Secondary LWCO’s may be required to meet local codes or CSD-1 requirements. A Warrick
26C1D1C Probe Type Low Water Cut-Off is used in steam applications to meet CSD-1 require-
ments and is also standard on steam units. Thread the remote sensor into the 1/2” NPT fitting
located on top of the boiler using a 1/2” x 3/8" bushing. See Table 1. for proper probe rod length.
Mount the control box to a side jacket panel on the boiler.
LENGTH OF PROBE ROD IN “MPH” SERIES BOILERS
BOILER MODEL MPH MPH MPH MPH
30/40 50/60 70/80 90/100
ROD LENGTH 14" 14" 14" 12"
TABLE 1
Other secondary LWCO’s include combination LWCO / Water Feeders. These devices are typ-
ically connected externally using an equalizing line, and piped into the available 1" NPT fittings
found in boiler top, and left side or front. Most commonly used combination units are McDonnell
& Miller 42 Series Pump Controls and Low Water Cut-Off or McDonnell & Miller No. 247-2 Feed-
er Combination. For piping diagram, see the List of Figures on the Table of Contents Page of
this manual.

MPH COLUMBIA BOILER COMPANY 8
NOTE:
Mount a combination unit so the low water cut-off line on the device is approximately 3 inch-
es above the lowest permissible water level plate found on the left side jacket panel of the
boiler. This point is also the center line of the 2" opening on the left side of the boiler.
Water Gauge
The water gauge is piped into the (2) 1/2” NPT fittings located on the M & M 157. During oper-
ation, the boiler’s water level should always be above the Lowest Permissible Water Level. Hot
water boilers do not require a Water Gauge.
Pressure Controllers
Low pressure, 15 PSI controls are supplied with steam units only. These controls consist of an
Operating Control and a Safety Limit. An additional operating control may also be supplied for
burners that function with low-high-low operation. Pipe the Pressure Controls and the 30 PSI
Steam Gauge using the supplied steam syphon to the 1/2" NPT fittings on the front of the boil-
er.
Aquastat Controllers®
Aquastat®Controllers are used to regulate boiler water temperature. Columbia supplies an
Operating Control and a Safety Limit Aquastat®with all hot water boilers and water heaters. An
additional Operating Aquastat®may also be supplied for burners that function with low-high-low
operation and/or steam boilers using an optional coil. Aquastat®’s are mounted in the 3/4" NPT
fittings located on the front of the boiler.
Safety Valve / Relief Valve
All safety or relief valves are located in the rear center fitting on top of the boiler. A 15 PSI Steam
Safety Valve is supplied for steam boiler and water heater applications. A 30 PSI Water Relief
Valve is used for hot water applications. The MPH 90/100 steam boiler will have two Safety
Valves. All safety and relief valves should be safely piped away from the boiler without reducing
the valve’s outlet port size.
Steam
Pipe the steam lines to the largest fitting or flange located on top of the boiler. Pipe the hot water
supply to the largest fitting or flange located on the top of the boiler.

MPH COLUMBIA BOILER COMPANY
9
Hot Water Connections
Use the fittings located on either side in the lower front of the boiler for the hot water return
from the system. Hot water applications also require the use of an expansion tank in the sys-
tem piping, to compensate for fluctuations in the water volume during heating and cooling cycles.
NOTE: Do not use lower rear fittings for returns.
Feed Water Supply
Virtually any unused port on the heat exchanger can be used for the feed water supply. In situ-
ations where make up water is needed, the water supply must be treated before it enters the
boiler to prevent the formation of scale, and to protect the boiler surfaces from the corrosive
effects of oxygenated water. Water treatment and a water treatment program must be adhered
to, or the life of the boiler will be effected. If a Condensate Return / Feedwater Tank is used,
connect the feedwater source to the float valve on the tank. Return to the section on water treat-
ment later in this manual.
Boilers with Coils
When ordered with coils, boilers are shipped with the coil(s) assembled to the coil plate(s), and
mounted in the boiler. MPH boilers 30 thru 80 HP can be furnished with one or two coils.
When making coil connections for twin coil units, manifold indirect water piping using copper
tubing and fittings connected in parallel. Pipe the outside coil openings together for cold water
inlets, and the inside coil openings for hot water outlets. If necessary, temper the hot water sup-
ply by using a mixing valve. Connect the hot water outlet source and a cold water supply line to
a mixing valve, to temper the hot water supply to the proper temperature requirements for
process equipment.
Whenever boilers are supplied with one or two coils, the coils must be covered by a minimum
of two inches of water, during normal operation, to allow proper heat transfer through the coil.
Adjust all LWCO piping to keep the coil(s) submerged in the event of a low water situation.
FUEL CONNECTIONS
OIL SUPPLY PIPING
Connect burner to oil supply. Refer to fuel unit manufacturer literature for piping, connections,
lift and tank installation. If such information is unavailable use the following guidelines:
Fuel supply “level with” or “above” burner: A single stage fuel unit connected to the fuel sup-
ply with a single supply line is the most common type of installation for these conditions. Man-
ual venting of the fuel oil is usually required on initial start up. Failure to vent air could result in
air lock/oil starvation.(One Pipe)
Fuel supply below the level of the burner: Use a single stage fuel pump in lift conditions of
up to 10 feet and a two stage pump when lift exceeds 10 feet. Both conditions require the use
of a return line which purges the fuel pump of air, returning it to the fuel tank. The “by-pass” plug
must be inserted into the fuel pump when installing a return line. (Two Pipe)

MPH COLUMBIA BOILER COMPANY 10
Fuel line installation: Consult the burner section of this manual for oil line type and sizing
requirements for proper operation. The size of oil lines is extremely important for proper opera-
tion. Continuous lengths of heavy wall copper tubing are recommended and should be installed
under the floor whenever possible. Fuel lines should not chaff the appliance or building struc-
ture.
All oil feed lines must be air tight. Use as few fittings as possible when assembling the oil lines.
Compression fittings allow more of a chance for air to be introduced into the oil supply and are
NOT recommended for use. The slightest air leak, usually caused by loose fittings or bad gas-
kets, can cause poor starts, smoky starts, sooting of burner parts, inefficient operation, and a
dangerous combustion condition. Always install fittings in accessible locations.
WARNING:
TEFLON®TAPE SHOULD NEVER BE USED WITH ANY OIL LINE CONNECTIONS. THE
USE OF TEFLON®TAPE ON BURNER COMPONENTS OR OIL SERVICE LINES WILL
VOID MOST BURNER WARRANTIES.
A vacuum test should be done on all installations to ensure that all fittings are tight and the oil
lines are of proper size. Suction vacuums must be held to acceptable limits. This is available
with the pump information supplied with the burner.
Fuel line valve and filter: (Not supplied) Install two high quality shutoff valves in accessible
locations on the oil supply line. Locate one close to the tank and the other close to the burner
ahead of the filter. Some filters come with built-in shutoff valves. Install a generous capacity fil-
ter inside the building between the fuel tank shutoff and burner.
For additional information consult the burner section of this manual.
GAS SUPPLY PIPING
Contact your local gas company to ensure that adequate gas service is available, and to review
applicable installation codes for your area.
The minimum gas supply pressure required by the burner is seven inches water column for all
Power Flame MPH Series burners. The maximum gas supply pressure to the Power Flame
burner is fourteen inches water column. Gas pressure greater than fourteen inches water col-
umn will require an additional gas pressure regulator to prevent damage to the primary gas reg-
ulator. Gas pressure below the minimum will cause combustion efficiency problems and should
be avoided if possible. Low gas pressure may also prevent the boiler from obtaining the desired
input rate, which will cause the boiler to be unable to produce the desired output. Consult the
factory if your gas supply pressure is not in the recommended range, or for pressure require-
ments for other burner manufacturers.
Use the following tables to determine the size of the main gas line required for the boiler that is
being installed. First determine the required input volume of gas needed at the gas manifold,
then determine the correct pipe size for the length of run needed.

MPH COLUMBIA BOILER COMPANY
11
REQUIRED INPUT - CUBIC FEET OF GAS PER HOUR
MPH MPH MPH MPH MPH MPH MPH MPH
GAS TYPE 30 40 50 60 70 80 90 100
NATURAL 1260 1680 2100 2520 2940 3360 3780 4200
PROPANE 495 659 824 989 1153 1318 1483 1647
CAPACITY OF PIPE - CUBIC FEET OF GAS OER HOUR AT 0.2" W.C. PRESSURE DROP
Equivalent 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
Length (ft)
10 425 725 1170 2360 4300 6250 12800
20 300 520 800 1700 3000 4500 9300
30 250 425 690 1400 2500 3750 7500
40 210 360 560 1200 2100 3200 6400
50 190 325 500 1100 1900 2850 5800
60 180 300 480 1000 1800 2300 4800
80 150 260 410 850 1550 2000 4200
100 135 230 370 750 1375 1680 3500
150 110 190 300 600 1100 1200 2750
200 75 165 260 540 950 1000 2000
Fitting Equivalent Lengths of Standard Pipe in Feet for Listed Fittings
Std. Tee 5.5 7.5 9.0 12.0 13.5 15 20
Std. Elbow 2.7 3.7 4.5 5.5 6.1 8 11
Vent lines, if required, are to be run outside the building, stopping clear of windows or
fresh air intakes. The vent should terminate in a way that will not allow the possibility of
water, dirt, insects, animals, and other matter from entering and clogging the vent pipe.

MPH COLUMBIA BOILER COMPANY 12
Gas lines should be tested for leaks using a soap solution. Your gas company may wish to wit-
ness this test. Do not exceed the maximum pressures allowed by the valve train.
Additional gas piping information is included in the burner section of this manual.
COMBUSTION AIR
It is essential that provisions are made for a fresh supply of outside air into the boiler room to
insure complete combustion, proper boiler efficiency, and a clean fire. Sufficient makeup air also
helps prevent nuisance shut-downs due to excessive combustion byproduct build-up on burner
parts. Outside air may be provided through ducts, fixed louvers or motorized louvers.
A rule of thumb for calculating fresh air openings to the outside is 63 sq. in. for every 100,000
BTUH gross output, or 21 sq. in. per boiler horsepower. The result of the above calculation is
expressed as free area, meaning no restrictions of any kind. If louvers or screens are used over
combustion air openings, calculate the percentage of free area to allow for these restrictions.
Do not have exhaust fans in the immediate proximity of the boiler room if at all possible, as
they will cause a reversal of draft through the boiler when the burner is cycled off. This draft
reversal draws heat from the combustion chamber back through the burner. This heat will dete-
riorate burner components prematurely, and eventually, burner operation will fail. The boiler
room should experience a positive pressure when the burner is not firing.
In situations where a boiler room experiences a negative pressure, use a direct air intake. A
direct air intake uses an adapter over the burner fan intake housing to draw in outside air
through duct work, from an external source. Consult burner manufacturer for parts and availabil-
ity.

MPH COLUMBIA BOILER COMPANY
13
REQUIRED BOILER MAKE-UP AIR
OPENING SQUARE HOLE ROUND PIPE
BTU INPUT MIN. SQUARE SQUARE HOLE ROUND PIPE
INCHES (APPROXIMATE) (APPROXIMATE)
MPH 30 1,260,000 630 26 X 26 30
MPH 40 1,680,000 840 30 x 30 34
MPH 50 2,100,000 1050 34 X 34 38
MPH 60 2,520,000 1260 36 X 36 40
MPH 70 2,940,000 1470 40 x 40 42
MPH 80 3,360,000 1680 42 X 42 46
MPH 90 3,780,000 1890 44 X 44 50
MPH 100 4,200,000 2100 46 X 46 52

MPH COLUMBIA BOILER COMPANY 14
CLEANING AND FILLING A NEW STEAM BOILER
Note: The following procedures are for steam boilers only.
In order to minimize the corrosive effects of raw water oxidation on the boiler, the water must be
heated to at least 180F immediately after entering the boiler, in order to drive off the corrosive
dissolved gases. This applies to all water - whether from a well, a spring, or from the local
municipal water system.
The oil and grease that accumulate in a new steam boiler can usually be washed out by either
procedure.
A. Skimming:
Since oil floats on water, skimming removes these oils from the water surface.
1. The 1" tapping on the back of the boiler can be used for skimming the water surface.
Install a ball valve and piping to a nearby drain.
2. Fill the boiler to the normal waterline.
3. With the boiler firing slowly open the ball valve installed at the skimmer port on the back
of the boiler.
4. Add water to the boiler at a rate that will allow the boiler to maintain a water temperature
between 180-200 F. Note do not add too much water so that the water level rises
above the skimmer tapping.
5. Continue to allow water to flow from the skim tapping until it appears to be oil free.
6. Once the water appears to be oil free, close the ball valve. The ball valve and piping to
the drain can be left in place or removed is so desired. If the skimming piping is to be
remove the water level must be lowered so that the piping can be removed safely. After
the skimming piping is removed plug the 1" fitting and fill the boiler back to it’s proper
water operating level.
B. Cleaning Compound:
1. Fill the boiler to the normal waterline.
2. Remove the safety valve.
3. Provide a boilout compound of caustic soda and trisodium phosphate in the proportions
of 2-1/2 lbs. of each chemical per 120 gallons of water.

MPH COLUMBIA BOILER COMPANY
15
EQUAL AMOUNTS
BOILER MODEL CAUSTIC SODA AND
TRISODIUM PHOSPHATE
MPH 30 3 lbs. 7 oz
MPH 40 4 lbs. 9 oz
MPH 50 5 lbs. 6 oz
MPH 60 6 lbs. 14 oz
MPH 70 7 lbs. 10 oz
MPH 80 8 lbs. 11 1/3 oz
MPH 90 10 lbs. 13 oz
MPH 100 10 lbs. 13 oz
CAUTION: USE CARE IN HANDLING THESE CHEMICALS. THE CAUSTIC SODA IS
EXTREMELY CORROSIVE TO SKIN AND CLOTHING. DO NOT PERMIT
EITHER THE DRY MATERIAL OR THE CONCENTRATED SOLUTION TO
CONTACT SKIN OR CLOTHING.
4. Mix the chemicals with water and pour into the boiler through the safety valve
opening.
5. Replace the safety valve.
6. Start the firing equipment.
7. Boil the water for at least five hours.
8. Stop the firing equipment.
9. Drain the boiler to a location where hot water can be discharged safely.
10. Wash the boiler thoroughly using a hose with sufficient pressure.
11. Fill the boiler to the normal waterline.
12. Add boiler water treatment as prescribed by a water treatment specialist.
13. Boil or bring water temperature to at least 180°F immediately.
14. The boiler is ready to put into service or on standby.

MPH COLUMBIA BOILER COMPANY 16
OPERATING THE BOILER
NOTE: Whether the boiler was purchased knockdown or factory packaged test fired,
each boiler must be "set up" for the conditions on location. Improper combus-
tion settings may cause the burner to operate erratically, resulting in boiler
shutdowns, lost time, and unnecessary service expenses.
PRE-START CHECKS AND INFORMATION
A new or relocated boiler should not be put into service until it has been inspected by an author-
ized inspector for the jurisdiction or the insurance company, and the required certificates have
been issued.
Whenever a new boiler is placed in service, operating data should be recorded and saved for
future reference. This information is extremely valuable for diagnosing problems if abnormal
operation occurs. Record all operating parameters such as pressures, stack temperatures, oxy-
gen or carbon dioxide levels, flows, draft, motor amps, damper positions, and interlock set
points. A burner start up and test information sheet has been included at the end of this section
for your convenience.
All cover plates, enclosures, and safety devices must be installed at all times during operation
and should only be removed while performing maintenance and/or service.
The fuel supply should not be turned on until the combustion chamber has been vented and the
pilot light (if gas ignited) checked for proper operation.
All drain valves including blowdown valves for stream boilers, water column drain valves, gauge
glass drain valves, and gauge cocks should be closed.
The safety/relief valves should be inspected externally to see that they are free to operate, and
that the discharge piping and drain piping are open to the atmosphere, and free to expand with-
out imposing a load on the safety valve bodies. Make sure the safety valve is piped to a safe
location to prevent injury.
The boiler feed pump(s) for steam applications should be checked to ensure that they are ready
for service. Check the data on rating plates of all electrical equipment to be certain the electri-
cal characteristics match those of the electric supply to which they are connected.
Before attempting start-up, carefully study the instructions included in the burner section of this
manual.
It is important to have the proper test equipment in order to adjust the combustion and pilot if
equipped. Those items that may be required include a manometer, micro ammeter, multimeter,
vacuum gauge, 0-300 PSI pressure gauge, carbon dioxide or oxygen analyzer, carbon monox-
ide tester, smoke gun, and stack thermometer.

MPH COLUMBIA BOILER COMPANY
17
STARTING THE BOILER
WARNING: NEVER OPERATE A BOILER WITHOUT BEING SURE IT IS FILLED WITH
WATER AND THAT PROPER WATER TREATMENT CHEMICALS HAVE BEEN
ADDED.
Allow the boiler to fill with water to its normal operating level.
Supply power to the boiler disconnects.
NOTE: The burner will not operate when the boiler has reached its normal water level, until
the reset button on the manually reset, probe type, low water cutoff is pushed.
NOTE: Combustion efficiency must be checked at this time. See the burner manufactur-
ers instructions for correct settings and more detailed information.
Follow the adjustment procedures outlined in the burner section of this manual to set up the
burner for proper operation.
STOPPING THE BOILER
To stop the boiler turn the main disconnect to the OFF position.