Burnham MPO Series, Installation & Service Instructions Manual

Page 1: ... r i a p e r r o e c i v r e s r o F g n i t a R n o n w o h s s a r e b m u N l a i r e S d n a r e b m u N l e d o M r e l i o B e d i v o r p r e l i o b n o n o i t a m r o f n i r e l i o b e h t f o p o t n o d e t a c o l l e b a L r e b m u N l e d o M r e l i o B r e b m u N l a i r e S r e l i o B e t a D n o i t a l l a t s n I _ _ _ _ _ O P M _ _ _ _ _ _ _ 6 r o t c a r t n o C g n i t...

Page 2: ...i v a h s e i t i r o h t u A l a u n a m n o i t c u r t s n i s i h t m o r f r e f f i d y a m s n o i t a l u g e R d n a e d a m e r a s n o i t a l l a t s n i e r o f e b d e t l u s n o c e b d l u o h s n o i t c i d s i r u j s d r a d n a t S g n i w o l l o f e h t o t e d a m e b d l u o h s e c n e r e f e r s e s a c l l a n I A B C D S R E L I O B A S U l i O f o n o i t a l l a t ...

Page 3: ... r e t a W d n a s l o r t n o C m i r T y l b m e s s A r e l i o B d e g a k c a P s l i a t e d r o f l a u n a m y l t c e r r o c e r a s l o r t n o c l l a t a h t e e s o t r o t c a r t n o c g n i l l a t s n i e h t f o y t i l i b i s n o p s e r e h t s i t I d e t e l p m o c s i n o i t a l l a t s n i e h t n e h w y l r e p o r p g n i t a r e p o e r a d n a d e l l a t s n i n o...

Page 4: ...o s d e l l a t s n i e b t s u m d n a n o i t a r e p o e f a s r o f r i a h s e r f s d e e n r e l i o b s i h T r i a n o i t a l i t n e v d n a n o i t s u b m o c e t a u q e d a r o f s n o i s i v o r p t o n d n a n w o d t u h s o t r e l i o b e h t e s u a c y a m h c i h w s l o r t n o c h t i w d e i l p p u s s i r e l i o b s i h T g n i t a e h e h t y t i l i b i s s o p a s ...

Page 5: ... n I e c i v r e S e c n a n e t n i a M 3 4 I I I g n i p i P m i r T r e l i o B r e t a W 1 2 X g n i n a e l C r e l i o B 5 4 V I g n i p i P r e t a e H r e t a W t c e r i d n I 5 2 I X g n i t o o h S e l b u o r T 7 4 V g n i t n e V 6 2 I I X s t r a P r i a p e R 8 4 I V l a c i r t c e l E 1 3 I I I X x i d n e p p A I I V g n i p i P l i O 3 3 f f O t u C r e t a W w o L 0 6 ...

Page 6: ...6 Figure 1 MPO 84 Thru MPO 231 Water Boiler ...

Page 7: ... e t a W e r u s s e r P g n i k r o W m u m i x a M d r a d n a t S y r o t c a F m o r F d e p p i h S I S P 0 3 l a n o i t p O I S P 0 5 l a n o i t p O I S P 0 4 r e l i o B o N l e d o M y t i c a p a C r e n r u B R B I T E N s g n i t a R s t n e m e r i u q e R y e n m i h C m u m i n i M E U F A H P G H B M g n i t a e H E O D H B M y t i c a p a C r e t a W H B M n I d n u o R a i D e l...

Page 8: ...om Jacket Left Side Panel 19 for burner swing door if opened fully with burner mounted otherwise 1 with burner removed 12 access clearance to service rear of boiler if right side clearance is less than 12 1 minimum if right side clearance is 12 or larger to access and service rear of boiler c Clearance from Jacket Right Side Panel 3 minimum if left side clearance is 12 or larger to access and serv...

Page 9: ... suitable for use on Beckett AFG with burner enclosure cover burner See Section V for installation details or b Outdoor air may be provided with the use of two permanent openings which communicate directly or by duct with the outdoors or spaces crawl or attic freely communicating with the outdoors Locate one opening within 12 inches of top of space Locate remaining opening within 12 inches of bott...

Page 10: ...tep 6 Lower pipe handles until front adjustable legs touch floor If necessary place wooden blocks under front legs before lowering to provide hand clearance Step 7 To lower rear of boiler tilt unit slightly forward by pushing on smokebox collar or lift pipes protruding through rear legs until wooden blocks can be removed see Figure 3 Slowly allow the weight of the boiler to tilt backward until rea...

Page 11: ...ment see Figure 4A Lift door off mounting bracket and set aside Remove mounting bracket and hardware from left side Remove upper jacket front panel retaining screw 5 16 x 1 2 lg Phillip Pan head machine screw from right side of door and re install in vacated upper mounting bracket tapping Do not tighten Move lower jacket panel retaining screw from right side to left tapping Do not tighten Rotate d...

Page 12: ...12 Figure 4B Top View Burner Swing Door Mounted to Cast Iron Block Assembly Jacket Removed for Clarity ...

Page 13: ... door can not be drawn in to provide an air tight seal as shown in Figure 4C Applying excessive torque will only cause thread damage E INSPECT SWING DOOR INSULATION AND ROPE GASKET 1 Open burner swing door using procedure previously outlined in Paragraph D of this section 2 Inspect fiberglass rope located on the swing door The rope must be evenly distributed around the perimeter of the door groove...

Page 14: ...n in Figure 5 Step e Insert two 2 brown thermostat wires and three 3 aquastat wires with Molex socket connector located on opposite end of aquastat harness through 7 8 dia blank knockout in jacket top panel Fish these wires to rear of internal junction box Insert snap in conduit connector in 7 8 blank knockout squeeze tabs on side of connector push into knockout and release tabs to lock connector ...

Page 15: ...optional equipment Burnham P N 100107 01 refer to Figure 8 Also refer to instructions provided with Auxiliary Dual Limit Control Kit If not required proceed to Paragraph 4 Step a Locate 1 2 NPT x 1 1 2 immersion well Apply thread sealant to 1 2 NPT male threads Thread well into 1 2 NPT boss on left side of supply manifold Using hex head tighten well until water tight Step b Locate L4080B Auxiliary...

Page 16: ...sert injector nipple Figure 7 Optional Equipment Low Water Cut Off LWCO Control Assembly Details Figure 8 Optional Equipment Auxiliary Limit Control Assembly Details into 2 NPT upper rear tapping on rear section engage 2 NPT male threads on end of manifold and hand tighten Note Based on system return piping and access to service boiler see Figure 1 and Figures 13A and 13B predetermine if manifold ...

Page 17: ... manifold Install 3 4 pipe plug not furnished in bottom tapping as shown see Figure 9 Step c Pipe discharge of relief valve as shown in Figures 13A and 13B Installation of the relief valve must be consistent with ANSI ASME Boiler and Pressure Vessel Code Section IV G N I N R A W d e p i p e b t s u m g n i p i p e g r a h c s i d e v l a v f e i l e R e r e v e s f o l a i t n e t o p e t a n i m ...

Page 18: ...ernal junction refer to Figures 6 and 20 Step c 24V thermostat field wiring will enter internal junction box through 5 16 snap bushing Figure 10 Piping Arrangement for Drain Valve and Indirect Water Heating Return located on rear panel adjacent to 7 8 dia knockout for power supply Step d Locate the two 2 brown wires labeled 24V Thermostat inside the internal junction box see Figure 6 these wires o...

Page 19: ...l l i w s e l f f a b e s e h T s e r u t a r e p m e t k c a t s r e w o l d n a s e i c n e i c i f f e s s o r g r e w o l a s n o i t i d n o c n i a t r e c r e d n U s a h y e n m i h c e h t g n i r e t n e e r u t a r e p m e t k c a t s w e d e h t w o l e b d e l o o c e b o t l a i t n e t o p e h t r o i r e t n i n o e t a s n e d n o c e t a e r c d n a t n i o p e v i s o r r o c s ...

Page 20: ...r into the opening of burner swing door Align and engage keyhole slot in burner flange over head of protruding cap screw Figure 12 Oil Burner Installation installed in previous Step Rotate burner to the right to lock flange behind head of cap screw Step g Align holes and install two 2 remaining cap screws Level burner and fully tighten all three 3 screws Step h Plug burner power cord into power ou...

Page 21: ...ating boiler using appropriate valves to prevent the chilled medium from entering the boiler See Figure 14 Also consult I B R Installation and Piping Guides 2 If this boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air the boiler piping must be equipped with flow control valves to prevent gravity circulation of boiler water during the op...

Page 22: ...22 Figure 13A Water Boiler Piping for Circulator Zoned Heating System Supply Side Circulator ...

Page 23: ...23 Figure 13B Preferred Water Boiler Piping for Zone Valve Zoned Heating System Supply Side Circulator ...

Page 24: ...ooling Refrigeration System To perform a long term pressure test including the boiler ALL trapped air must first be removed from the boiler A loss of pressure during such a test with no visible water leakage is an indication that the boiler contained trapped air ...

Page 25: ...igures 15A and 15B Figure 15A Alliance Water Heater Piping w Supply Side Circulator on Circulator Zoned Heating System Also refer to Figures 13A and 13B 1 Refer to Alliance manual for additional information Figure 15B Alliance Water Heater Piping w Supply Side Circulator on Zone Valve Zoned Heating System ...

Page 26: ...mined by a qualified person in accordance with the requirements of Chapter 11 of NFPA 211 Standard for Chimneys Fireplaces Vents and Solid Fuel Burning Appliances SECTION V VENTING a Loose Mortar Loose mortar could be an indication of a prior history of condensing flue gases upon the inside walls of the chimney Colder climates are more susceptible to this condition Under no circumstances shall a c...

Page 27: ...27 Figure 16 Recommended Vent Pipe Arrangement and Chimney Requirements Figure 17 Proper and Improper Locations of Draft Regulator ...

Page 28: ...ty to create condensate The higher the stack temperature the greater the amount of draft that can be generated A lower stack temperature not only reduces the amount of draft that can be created but it also increases the possibility that the flue gases could condense in the chimney connector or stack 2 NFPA 31 and CSA B139 04 have information to help the installer make an appropriate choice of vent...

Page 29: ...t n i r i a f o e z i s e c u d e r t o n o D w o l l o f d n a d n a t s r e d n u d a e R s n o i t c i r t s e r n o i t c u r t s n i r i a n o i t s u b m o c n o i t a l l a t s n I e r P e h t n i d e n i a t n o c l a u n a m s i h t f o n o i t c e S 1 General a Use 4 dia single wall galvanized metal pipe and fittings available at most heating distributors for air intake piping Maximum al...

Page 30: ...aced 6 Install air intake terminal See Figure 19 E C I T O N s e h c n i 2 1 t s a e l t a e b t s u m l a n i m r e t e k a t n I n o i t a l u m u c c a w o n s s u l p e d a r g e v o b a 7 Seal all external joints with weatherproof caulk G N I N R A W m u e l o r t e p e r e h w e k a t n i r i a e t a c o l t o n o D e l i t a l o v s t n e g r e t e d s C F C s e t a l l i t s i d t n e s e ...

Page 31: ...und this control Heat Anticipator in Thermostat should be set to match the requirements of the control to which it is connected See Figure 20 for desired system and heat anticipator setting If system tends to overheat above the thermostat s temperature setting reduce heat anticipator setting by 1 or 2 amps If system tends to short cycle without reaching desired room temperature increase heat antic...

Page 32: ... boiler equipped with Optional L4080B Auxiliary High Limit Control if boiler water temperature exceeds the operating limit setting and reaches the high limit setting the circulator will continue to operate and the burner will stop until the high limit is closed by an 8 F drop in boiler water temperature On burner start if the cad cell does not see fl ame within approximately 15 seconds primary con...

Page 33: ...or On many occasions a leaky oil delivery line can introduce air into the fuel oil supply system This often creates a rough starting condition and can create a burner lockout state In addition to fixing the leak a fuel line deaerator can be installed to eliminate air The single line from the fuel tank is connected to the deaerator The burner pump must be connected to the deaerator as a two pipe sy...

Page 34: ... t f i L 5 2 g i F e e S g n i b u T f o h t g n e L m u m i x a M 5 2 e r u g i F e e S R H D O 8 3 H P G 3 g n i b u T D O 2 1 H P G 3 g n i b u T 0 3 9 0 0 1 2 5 8 0 0 1 4 7 7 0 0 1 6 9 6 0 0 1 8 0 6 0 0 1 0 1 2 5 0 0 1 2 1 4 4 0 0 1 4 1 6 3 0 0 1 6 1 7 2 0 0 1 8 1 6 7 H t f i L 5 2 g i F e e S g n i b u T f o h t g n e L m u m i x a M 5 2 e r u g i F e e S R H D O 8 3 H P G 3 g n i b u T D O 2...

Page 35: ... I N R A W l l a w o l l o f d n a d n a t s r e d n u d a e r y l e t e l p m o C e r o f e b l a u n a m s i h t n i s n o i t c u r t s n i p u t r a t s g n i t p m e t t a B FILL HEATING SYSTEM WITH WATER E C I T O N l i o e h t e v o m e r y l r e p o r p o t t n a t r o p m i s i t I n a e l c o t e r u l i a F m e t s y s e h t m o r f t r i d d n a s t n e v r i a d e g g o l c n i t l u ...

Page 36: ... any key pressed the display will enter a dim display mode To return to the bright display mode simply press any key r o r r E e d o C n o i t c A e s u a C 1 r r E r o s n e s k c e h c t l u a f r o s n e S 2 r r E g n i r i w M O C a r i v n E k c e h c t l u a f M O C E 3 r r E l o r t n o c e c a l p e r t l u a f e r a w d r a H TABLE 5 LED ERROR CODES d The operating sequence for L7248C is ...

Page 37: ...c e h c m e t s y s s n o i t c e n n o c e h t n i n o i s o r r o c Figure 25 L7248C Setpoint and Differential Switching Action TABLE 6 L7248C CONTROLLER OPERATING SEQUENCE 3 TURN ON BURNER service switch and allow burner to run until oil flows from vent fitting in a SOLID stream without air bubbles for approximately 10 seconds NOTE For Primary Control Pump Priming Cycle details see Paragraph I ...

Page 38: ...38 Figure 27 L1 L2 and V1 Head Electrode Positioning and Gun Setting Beckett AFG ...

Page 39: ...en fuel unit and nozzle will compress when burner is on and will expand when burner stops causing oil to squirt from nozzle at low pressure as the burner slows down and causing nozzle to drip after burner stops Usually cycling the burner operation about 5 to 10 times will eliminate air from the oil line 2 IF NOZZLE CONTINUES TO DRIP repeat Paragraph H No 1 If this does not stop the dripping remove...

Page 40: ...econds off Device tries to restart system after approximately 60 seconds After third Recycle Mode trial safety switch locks out within safety switch timing indicated on label and control enters Restricted Mode Indicator light flashes at 1 Hz rate second on second off Ignition and motor stop and oil valves closes To reset from Restricted Mode Press and hold the reset button for 30 seconds When the ...

Page 41: ...o m e r e b t s u m r e p m u J Hydrolevel 1150 probe low water cut off operational test procedure a Before raising the water level above the Model 1150 turn on power to the boiler and set the thermostat to call for heat Both the green POWER LED and amber LOW WATER LED should illuminate The burner should not fire IMPORTANT If the burner fires with no water at the probe immediately shut down power ...

Page 42: ...othing 3 Gloves 4 Eye Protection Take steps to assure adequate ventilation Wash all exposed body areas gently with soap and water after contact Wash work clothes separately from other laundry and rinse washing machine after use to avoid contaminating other clothes Discard used RCF components by sealing in an air tight plastic bag First Aid Procedures If contact with eyes Flush with water for at le...

Page 43: ... LWCO tapping k Mount the low water cut off control on the probe l Reconnect the control to probe wiring m Fill the system with water n Add boiler water treatment compound as needed refer to Paragraph B o Restore electric service to the boiler p Fire burner to bring the water in the boiler to a boil to drive off free oxygen q WARNING BEFORE RETURNING BOILER TO SERVICE Follow the low water cut off ...

Page 44: ...chemical supply house or through your local druggist The pH should be higher than 7 but lower than 11 Add appropriate water treatment chemicals if necessary to bring the pH within the specified range With this lower level of protection care must be exercised to eliminate all of the free oxygen in the system 5 Boiler is now ready to be put into service C FREQUENT WATER ADDITION Although unusual for...

Page 45: ...ining debris as necessary Inspect burner swing door insulation and rope gasket for signs of damage If damaged replace as needed D REASSEMBLE BOILER N O I T U A C r e n r u b e h t s s e l n u r e n r u b e h t t r a t s t o n o D e r a s e t a l p r e v o c y p o n a c d n a r o o d g n i w s e c a l p n i d e r u c e s 1 Insert the baffles if originally installed into the correct flue way The baf...

Page 46: ...a e h e h t f o t r a t s e h t e r o f e b d e n a e l c d n a d e t c e p s n i e b t s u m e u l f y e n m i h c e h t n a e l c A s n o i t c u r t s b o y n a r o f n o s a e s g n i t a e h e h t t u o h g u o r h t y l l a c i d o i r e p d e t c e p s n i e b d l u o h s r o y r u j n i e s u a c d l u o c t a h t s e m u f s u o i x o n w o l l a o t y r a s s e c e n s i e u l f y e n m ...

Page 47: ...pump but more importantly water doesn t burn It chills the flame and causes smoke and unburned fuel to pass out of the combustion chamber and clog the flueways of the boiler SECTION XI TROUBLE SHOOTING 8 COLD OIL If the oil temperature approaching the fuel pump is 40 F or lower poor combustion or delayed ignition may result Cold oil is harder to atomize at the nozzle Thus the spray droplets get la...

Page 48: ...n k n o i t a u t c a e v l a v l i o f o s d n o c e s l l i w t u o k c o l I F T n o i t i n g I r o F l a i r T s a d e r a y b d e t a c i d n i s i t u o k c o L r u c c o y r a m i r p l i o e h t n o d e t a c o l n o d i l o s D E L l o r t n o c s k c o l l o r t n o c e h t f i r u c c o l l i w p u h c t a L r o f l l a c a g n i r u d s e m i t 3 e e r h t t u o n o y d a e t s y b d ...

Page 49: ...49 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 50: ...50 Bare Boiler Assembly ...

Page 51: ...a l P S S U r e h s a W t a l F 8 3 n o m m o C e r a w d r a H 4 4 4 4 H 1 n i a l P t u N x e H y v a e H 6 1 8 3 4 4 4 4 J 1 s t r e s n I d e d a e r h T w r a B r e n n a p S g L 8 3 4 1 x 2 1 1 x 4 1 1 1 0 2 1 0 0 0 1 2 s t r e s n I d e d a e r h T w r a B r e n n a p S g L 8 3 0 2 x 2 1 1 x 4 1 1 2 0 2 1 0 0 0 1 2 s t r e s n I d e d a e r h T w r a B r e n n a p S g L 8 3 6 2 x 2 1 1 x 4 ...

Page 52: ...52 Bare Boiler Assembly ...

Page 53: ...e H t e k c o S g L 8 5 x 8 1 6 1 5 d e t a l P 2 2 2 2 Y 1 d e t a l P t l o B p a T g L 4 3 1 x 6 1 8 3 n o m m o C e r a w d r a H 2 2 2 2 Z 1 d e t a l P S S U r e h s a W t a l F 8 3 2 2 2 2 A A 1 x o b e k o m S 1 0 1 2 0 0 0 1 1 1 1 1 B B 1 n i a l P S S U r e h s a W t a l F 6 1 5 n o m m o C e r a w d r a H 4 4 4 4 C C 1 n i a l P w e r c S p a C g L 8 7 x 8 1 6 1 5 4 4 4 4 D D 1 s s a r ...

Page 54: ...54 Jacket Assembly ...

Page 55: ...e s s A k c o l B n o r I t s a C n o i t c e S 2 1 0 6 1 0 0 0 1 1 y l b m e s s A k c o l B n o r I t s a C n o i t c e S 3 2 0 6 1 0 0 0 1 1 y l b m e s s A k c o l B n o r I t s a C n o i t c e S 4 3 0 6 1 0 0 0 1 1 y l b m e s s A k c o l B n o r I t s a C n o i t c e S 5 4 0 6 1 0 0 0 1 1 M 2 d e r i u q e R n o i t a l u s n I o N y l b m e s s A l e n a P e d i S t e k c a J r e l i o B n ...

Page 56: ...56 MPO84 Thru MPO231 Water Boilers Trim and Controls ...

Page 57: ...P N 2 1 1 d l o f i n a M y l p p u S n o r I t s a C 1 0 2 8 0 0 0 1 1 1 1 1 M 3 l l e W n o i s r e m m I A 0 7 8 3 2 1 l l e w y e n o H n o i t a l u s n I 2 1 1 x T P N 4 3 6 2 4 0 6 1 0 8 1 1 1 1 N 3 4 1 0 1 C 8 4 2 7 L l l e w y e n o H y l b m e s s A s s e n r a H l o r t n o C y a l e R c r i C t i m i L h g i H 1 0 5 8 0 0 0 1 1 1 1 1 e t o N 4 1 0 1 C 8 4 2 7 L l l e w y e n o H y l n ...

Page 58: ...58 Beckett AFG Burner ...

Page 59: ... y l b m e s s A r e c a p S r e d i p S 3 0 5 5 3 0 5 5 3 0 5 5 3 0 5 5 e t a l P n o e h c t u c s E 3 9 4 3 3 9 4 3 1 4 9 5 1 4 9 5 y l b m e s s A e t a l P g n i t s u j d A d a e H 5 9 8 1 5 2 1 9 5 3 1 9 5 G 3 1 9 5 G s w e r c S d a e H 1 2 2 4 1 2 2 4 1 2 2 4 1 2 2 4 t e k s a G e g n a l F 8 8 3 2 3 8 8 3 2 3 8 8 3 2 3 8 8 3 2 3 g n i s u o H G F A 4 7 8 5 4 7 8 5 4 7 8 5 4 7 8 5 r o t o...

Page 60: ...ictions require the use of a LWCO with every hot water boiler Where The universal location for a LWCO on both gas and oil hot water boilers is above the boiler in either the supply or return piping The minimum safe water level of a water boiler is at the uppermost top of the boiler that is it must be full of water to operate safely Provisions have been made on the MPO supply manifold for a LWCO Wh...

Page 61: ...61 Figure A2 LWCO Location ...

Page 62: ...62 SERVICE RECORD DATE SERVICE PERFORMED ...

Page 63: ...n 5 6 0 0 0 4 0 0 0 2 0 0 9 8 1 O P M 5 3 1 0 1 V 7 2 B 0 6 x 0 1 1 o g a H 0 5 1 5 1 1 2 d n 9 3 0 0 0 4 0 0 0 3 0 0 1 3 2 O P M 5 6 1 3 1 V 7 2 B 0 6 x 5 3 1 o g a H 0 5 1 5 1 1 2 d n 8 1 0 0 0 5 0 0 0 3 0 0 s e t o N t a 4 8 O P M 1 e l f f a b e r i f w o l a s e z i l i t u e t a r g n i r i f H P G 0 6 0 O C 5 1 1 d n a F 0 8 1 f o e r u t a r e p m e t y l p p u s t n a t s n o c a n o d e ...

Page 64: ...IGHTS WHICH VARY FROM STATE TO STATE Limited Warranty FOR RESIDENTIAL CAST IRON WATER BOILERS 03 03 Subject to the terms and conditions set forth below U S Boiler Co Inc Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a residential grade water boiler manufactured and shipped on or after July 1 1991 ONE YEAR LIMITED WARRANTY ON RESIDENTIAL GRADE WATER...