Burnham MPC Instruction Manual

101786-01R7 - 11/14Price - $5.00Commercial Boilerswww.burnhamcommercial.comDNAGNITAREPO,NOITALLATSNIROFSNOITCURTSNIECIVRESSSAP-ITLUM™CPMledoMRELIOBNOR

10Figure 1b: Dimensional Information* Wiring harness shown in this location for illustration purposes - typically, wiring harness leads will exit jac

100Figure 64: MPC Standard 50 PSI Trim and Control with 30 PSI and 80 PSI Working Pressure Trim Options (continued)

101REPAIR PARTS - STANDARD WATER TRIM & CONTROL AND OPTIONAL WORKING PRESSURE TRIM (continued)Item No.DescriptionBoiler Sections / Qu

102Figure 65: MPC Optional Controls

103REPAIR PARTS - COMMON OPTIONAL CONTROLSItem No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 Probe

104Appendix A - FiguresFigure Number Page Number DescriptionEquipment Check ListFigure 1a 2 Carton IdenticationSection

105Figure Number Page Number DescriptionSection III - Boiler Assembly Instructions (Knockdown Boiler) (continued)Figure 25 42 In

106Figure Number Page Number DescriptionSection VIII - Repair PartsFigure 55 76 MPC Cast Iron Section AssemblyDescription 77 Cast Iron Section Assemb

107Appendix B - TablesTable Number Page Number DescriptionSection I - General InformationTable I 11 Dimensional InformationTable I

108

11SECTION I - GENERAL INFORMATIONBoiler ModelNumber of SectionsDim. A(Inches)* Burner Dimension B (Inches)Minimum Flue Bafe Installation Clear

12Model MPC™ BoilersBoiler ModelBoiler HorsepowerBurner InputGross Output (MBH)Net I=B=R Rating (MBH)Thermal EfciencyHeating Surface(Sq. Ft.)Net Furn

13SECTION I - GENERAL INFORMATION (Continued)A. INSPECT SHIPMENT carefully for any signs of damage.1. ALL EQUIPMENT is carefully manufactured, insp

14Table V: Minimum Installation Clearances To Combustible Materials (Inches) per UL726 (Packaged / Firetested Boiler)CA B

15a. In the absence of local requirements, the conned space shall be provided with two permanent openings, one in or near the top of the room and on

16Figure 3b: Vents - Faults and SuggestionsVenting Instructions are recommendations only. Consult a venting expert on the design of a specic vent sy

17A. FACTORY ASSEMBLED SECTIONS - The assemblage should be set in the proper location as outlined in Section I. Lifting arrangement and weights are

18 Then proceed to Step C of this section on Page 24, “HYDROSTATIC TEST”.B. FIELD ASSEMBLED SECTIONS - If the boiler was ordered knockdown, t

19Figure 5: Manual or Hydraulic Draw-up Section Assembly

2IMPORTANT INFORMATION - READ AND SAVE THESE INSTRUCTIONS

20Figure 6: Vertical Bracing of Rear SectionFigure 8: Inspection Pad Locations forSection Draw-upFigure 7: Setting of Nipples

21This is a forced draft red boiler and sealant must be applied where specied for proper and safe performance. Burnham Commercial has approv

22adjacent sections as the boiler operates with a positive pressure in the rebox and products of combustion will escape between sections unless they

232. ASSEMBLY OF SECTIONS (HYDRAULIC DRAW-UP) • MPC4 through MPC12 Section Assemblies The entire assemblage may be drawn-up at one time using

24Step f. After all sections have been drawn up, retention rods must be installed. Do not release hydraulic pressure until the retention rods are in

25SECTION III - BOILER ASSEMBLY INSTRUCTIONS (Knockdown Boiler)Figure 9: Installation of Common Parts to Block Assembly

26A. INSTALL COMMON PARTS TO BLOCK ASSEMBLY, Refer to Figure 9.1. Remove contents from Common Parts Carton marked ‘CPC’.2. Locate four (4) C. I

27f. Install observation port sight glass. Locate 2” x 2-1/2” lg. nipple, sight glass envelope and 2” conduit bushing. Thread 2” nipple into observ

28Table VII: Modular Return Water Mixing Tube (RWMT RC)

29Figure 13: Return Water Mixing Tube RC Assembly and Installation

3This 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 se

30Repeat this process for each joint, securing the previous assembly to the tube shown in next column to the right in Table VII, also refer to Figure

315. Add front/center section mounting hardware to all but one (1) horizontal support channel assembly. Lay channel assembly on oor with brackets f

32Figure 17a: Front/Center Section HorizontalChannel Assembly w/Mounting HardwareFigure 17b: Rear Section Horizontal ChannelAssembly w/Mounting Hard

33Figure 18a: Mount Front/Center Section Horizontal Channel to Block AssemblyFigure 18b: Mount Rear Section Horizontal Channel to Block Assembly

34Figure 19: Attachment of Lower Front/Center Section Bracket to Casting LegFigure 20: Attachment of Lower Rear Section Bracket to Casting Leg

35 Hand tighten one (1) 5/8” washer and hex nut on bolt. Do not wrench tighten at this time. Repeat for all front/center brackets, both sides.11.

36Figure 22: Lower Tie Bar Installation Repeat operation until all vertical channels have been installed. Using an open end wrench and ratchet with

37D. Locate and Install Heat Exchanger (Block Assembly) Insulation Wrapper(s), see Figure 23.1. 4 thru 6 Section Block Assembly - Insulation wrapper

38E. Installing Internal Wiring Harness for Control/Safety Circuits - refer to Figures 24a through 24g.1. See Figure 24a for layout of Internal wiri

393. Locate chaseway channel(s) shipped in Jacket Carton marked ‘JC-2’, see Figures 24c and 24d. Identify main chaseway channel by it’s unequal ends

4Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, ald

40Figure 24e: Internal Wiring Harness Components - Install Protective Edging Install 1-13/16” lg. pieces on horizontal raw edges at both ends of cha

41Figure 24g: Internal Wiring Harness Components - Secure Harness to Vertical Channel Insert rst set of harness connectors through opening in rear

42c. BSD with right hand hinge arrangement - harness exits right side of jacket front panel en route to control panel.d. BSD with right hand hinge a

43Table X: Jacket Top Corner / Intermediate Panel ArrangementBoiler SizeSide of BoilerOrder of Assembly (* See Panel Designation Below)Front

44Step 5. On 12 thru 18 Section Boilers, locate top intermediate panel(s) #3 per Table X and secure to panel #1 and each other using two (2) #8 x ½”

45Figure 28: Jacket Split Rear Panel DetailFigure 29: Install Jacket Split Rear PanelH. Locate Jacket Split Rear Panel shipped in JC-1 Jacket Carto

46Step 1. Position front panel at approximately 30° angle, hook front ange under clips on outer top corner panels as shown in Figure 30a, Detail A,

47L. Install Burner Swing Door (BSD) on Block Assembly hinges, see Figure 31. Move BSD to front of boiler. Position door on the Floor, standing up,

48Important Product Safety InformationRefractory Ceramic Fiber ProductThe Repair Parts list designates parts that contain refractory ceramic fibers (R

49Figure 33: Install 2nd Pass Flueway BafesFigure 32: Install 3rd Pass Flueway Bafes (4 thru 11 Section Boilers Only)2. On 4 thru 18 Section Boil

5EQUIPMENT CHECK LIST This Equipment Check List has been provided so that the Installer can determine if all parts have been provided for the boiler

50N. Close Burner Swing Door and secure using (4) 5/8” at washers, (4) 9/16” lock washers and (4) 9/16 - 12 x 2” lg. cap screws as shown in Figure 3

511. In most cases the burner adapter plate carton for the specied burner will be provided by Burnham.2. If adapter is provided by Burnham, open ca

521. Harness is split into two (2) 7 wire bundles that exit side of front panel as shown in Figure 25.2. Each seven (7) wire harness bundle must be

53 Note: Supply manifold must be installed with 1½” couplings aligned with front and rear axis of boiler.2. Apply thread sealant and install temper

54S. Installing Optional Controls (if applicable):1. Install M&M 750P-MT-120 Probe Low Water Cut Off (LWCO)a. Apply thread sealant to ¾” probe

55c. Connect opposite end of L4006B Low Fire Hold Control harness to right side junction box cover ‘A’, hole location #2 as shown in Figure 40.d. Lo

56v. Connect opposite end of T991A Modulating Control harness to right side junction box cover ‘A’, hole location #4 as shown in Figure 40.vi. Locat

57U. Install Optional Split Jacket Panels for Burner Swing Door (BSD) Cover (if applicable).1. Open carton and remove contents.2. Locate hanger bra

58* Width can vary with gas train conguration.** Varies slightly with burner and gas train conguration.1. Do not tilt. Exercise caution when lift

59Figure 49a: Recommended MPC Minimum Piping - Single Boiler Application NOTES:1. All piping is schedule 40.2. Pipe sizes listed are based on

6KNOCKDOWN BOILER - EQUIPMENT CHECK LIST (Continued)Component DescriptionCarton Designation on Bar Code LabelPart NumberQty. Req’d. Per Boiler Size

60Boiler Operating Requirements:• Minimum Return Water Temperature = 80°F• Maximum Delta T = 80°F• Minimum Supply Water Temperature = 130°FFigure 4

61Figure 50a: Alternate MPC Minimum Piping - Single Boiler ApplicationBoiler ModelSupply / Return20°F Rise 40°F RiseNom. I.D. (Inch)Wat

62Boiler Operating Requirements:• Minimum Return Water Temperature = 80°F• Maximum Delta T = 80°F• Minimum Supply Water Temperature = 130°FFigure 5

63a. Temperature and Flow Requirements – An existing parallel piping system may be used, provided the return water is not below 80°F and the return w

64C. BOILER PIPING, DOMESTIC HOT WATER (DHW) APPLICATION – The MPC boiler can be used in many different piping applications to produce Domestic

65SECTION V - OPERATING INSTRUCTIONSA. ALWAYS INSPECT INSTALLATION BEFORE STARTING BURNER.B. FILL HEATING SYSTEM WITH WATER.1. CLEAN HEAT

66E. TEST CONTROLSBefore installation of the boiler is considered complete, the operation of the boiler controls should be checked, particularly the

67 The pH should be higher than 7 but lower than 11. Add some appropriate water treatment chemicals, if necessary, to bring the pH within the speci

68SECTION VI - SERVICE INSTRUCTIONS IMPORTANT - See Section V, Item (G) under Operating Instructions, if it becomes necessary to add water to the boi

69f. Use a wire or ber bristle brush of appropriate length and diameter to allow sufcient cleaning of all ue passages. Using long strokes, push t

7KNOCKDOWN BOILER - EQUIPMENT CHECK LIST (Continued)Component DescriptionCarton Designation on Bar Code LabelPart NumberQty. Req’d. Per Boiler Size

70Exercise caution when handling phosphoric acid and follow the instructions on container label. Always use protective clothing and equipment when wo

71Table XII: Recommended Periodic Testing Check ListItem Frequency Accomplished by RemarksGauges and Indicators Daily Operator Make visual inspection

72Table XII: Recommended Periodic Testing Check List (continued)Item Frequency Accomplished by RemarksHigh Limit Safety Control Annually Service Tech

73SECTION VII - BURNER SPECIFICATIONSBOILER MODELBURNER MIN. INPUT (GPH)BURNER MAX. INPUT (GPH)BURNER MODELAIR TUBECOMB.BURNER SETTINGSPUMPPRESSURE

74BOILER MODELBURNER MIN. INPUT (GPH)BURNER MAX. INPUT (GPH)BURNER MODELDIFFUSER OPENING (IN.)APPROX. HIGH FIREDAMPER SETTING - TOP / BOTTOM DAMPER (I

75BOILER MODELBURNER INPUT **BURNER MODELDIFFUSER OPENING (IN.)APPROX. HIGH FIRE DAMPER SETTING -TOP / BOTTOM DAMPER

76SECTION VIII - REPAIR PARTS All MPC™ Repair Parts may be obtained through your local Burnham Commercial Cast Iron Wholesale distributor. Should yo

77Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 MPC-R Rear Section (Machined) 1 1 1 1 1 1 1 1 1 1

78Figure 56: MPC Common Bare Boiler Components

79REPAIR PARTS - COMMON BARE BOILER COMPONENTSItem No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181

8TABLE OF CONTENTSSECTION I - GENERAL INFORMATION Dimensional Information ...

80Figure 56: MPC Common Bare Boiler Components (continued)

81Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 1820 9/16” Split-Lock Washer, Plated 4 4 4 4 4 4 4 4

82Figure 57: MPC Front & Center Section Frame Rail Assembly

83Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 Jacket Frame-Horizontal Support Channel 1 1 1 2 2

84Figure 58: MPC Rear Section Frame Rail Assembly

85Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 Jacket Frame-Horizontal Support Channel 1 1 1 1 1

86Figure 59: MPC Return Water Mixing Tube RC Assembly

87REPAIR PARTS - RETURN WATER MIXING TUBE RC ASSEMBLYBoiler ModelReturn Water Mixing Tube Assembly, Flared Collar Return Water Mixing Tube Ass

88Figure 60: MPC Heat Exchanger Insulation Wrapper

89Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 Complete Heat Exchanger Wrapper Insulation

9TABLE OF CONTENTS (continued)SECTION VI - SERVICE INSTRUCTIONS Cleaning Boiler Heating Surfaces ...

90Figure 61: MPC Internal Wiring Harness Components

91Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 Primary Internal J-Box 1 1 1 1 1 1 1 1 1 1 1 1 1

92Figure 62: MPC Jacket Panel Assembly

93REPAIR PARTS - JACKET PANEL ASSEMBLYItem No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 Jacket Fro

94Figure 62: MPC Jacket Panel Assembly (continued)

95REPAIR PARTS - JACKET PANEL ASSEMBLY (continued)Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 18

96Figure 63: MPC 2nd and 3rd Pass Flueway Bafes

97Item No.DescriptionBoiler Sections / QuantityPart No.04 05 06 07 08 09 10 11 12 13 14 15 16 17 181 2nd Pass Flueway Bafes, 304 Stainless Steel:1A.

98Figure 64: MPC Standard 50 PSI Trim & Control with 30 PSI and 80 PSI Working Pressure Trim Options

99REPAIR PARTS - STANDARD WATER TRIM & CONTROL AND OPTIONAL WORKING PRESSURE TRIMItem No.DescriptionBoiler Sections / QuantityPart No.