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Burnham MPC, Installation And Operation Manual

The Calpeda MPC is a reliable and efficient pump control panel designed for various applications. To ensure seamless operation, it comes with a comprehensive Operating Instructions Manual which can be freely downloaded from manualshive.com. This user-friendly manual provides step-by-step guidance for optimized performance and hassle-free maintenance.

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81

Item 

No.

Description

Boiler Sections / Quantity

Part No.

04

05

06

07

08

09

10

1

1

12

13

14

15

16

17

18

20

9/16” Split-Lock W

asher

, Plated

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

101760-01

20A

5/8” Flat W

asher

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

80860608

21

9/16” -12 x 2” Lg. Hex Head Cap Screw

, Plated

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

101761-01

22

Burner 

Adapter Plate Cartons (Includes Item 23):

Oil Burner

22A.  Beckett (“CF”) BAP

 No. “00”, 6-3/4” Dia. Hole

1

1

1

1

602263001

22B.  Beckett (“CF”) BAP

 No. “01”, 8-1/4” Dia. Hole

1

1

1

1

1

1

1

1

60226301

1

22C.  Beckett (“CF”) BAP

 No. “02”, 10-1/4” Dia. Hole

1

1

1

602263021

Gas Burner

22D.  Beckett (“CG”) BAP

 No. “03”, 5” Dia. Hole

1

1

602263031

22E.  Beckett (“CG”) BAP

 No. “04”, 6” Dia. Hole

1

1

602263041

22F

.  Beckett (“CG”) BAP

 No. “07”, 7-1/4” Dia. Hole

1

1

1

1

602263071

22G.  Beckett (“CG”) BAP

 No. “08”, 8-1/8”” Dia. Hole

1

1

1

1

1

1

1

602263081

- OR -

Oil, Gas, Gas/Oil Combo Burner

22H.  Power Flame (“C”) BAP

 No. “40”, 7-1/2” Dia. Hole

1

1

1

1

602263401

22 I.  Power Flame (“C”) BAP

 No. “41”, 9” Dia. Hole

1

1

1

1

1

1

1

60226341

1

22J.  Power Flame (“C”) BAP

 No. “42”, 10-3/8” Dia. Hole

1

1

1

1

602263421

- OR -

Gas Burner

22K.  Power Flame (“JR”) BAP

 No. “45”, 6-3/8” Dia. Hole

1

1

1

1

602263451

22L.  Power Flame (“JR”) BAP

 No. “41”, 9” Dia. Hole

1

1

1

1 

60226341

1

23 

  

Burner 

Adapter Plate Gasket 

(RCF)

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

8022601

24

3/8” Split-Lock W

asher

, Plated

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

80860650

25

3/8” -16 x 7/8” Lg. Hex Head Cap Screw

, Plated

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

80861352

26

1/2” Flat W

asher (USS), Plated

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

80860641

27

1/2”-13 Hex Nut, Plated

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

80860471

28

3” NPT

 Countersunk Pipe Plug, Black

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

806603509

29

Flue Outlet Damper 

Assembly

, 7”

1

1

102471-01

Flue Outlet Damper 

Assembly

, 8”

1

1

1

102471-02

Flue Outlet Damper 

Assembly

, 10”

1

1

1

102471-03

Flue Outlet Damper 

Assembly

, 12”

1

1

1

1

1

1

1

102471-04

30

Flue Outlet Damper Mounting Gasket

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

102472-01

31

Hex Head Cap Screw 5/16 - 18 x 7/8” Plated

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

80861371

32

W

asher

, Flat, 1/4” USS, Plated

12

12

12

12

12

12

12

12

12

12

12

12

12

12

12

80860803

33

4” NPT

 x 8” Lg - Supply/Return

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

806600603

REP

AIR  P

ARTS  -  COMMON  BARE  BOILER  COMPONENTS (continued)

Summary of Contents for MPC

Page 1: ... i o B e d i v o r p r e l i o b 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 _ _ _ _ _ _ C P M _ r o t c a r t n o C g n i t a e H e p y T l e u F f o s s e r d d A r e b m u N e n o h P Commercial Boilers www burnhamcommercialcastiron com D N A G N I T A R E P O N O I T A L L A T S N I R O F S N O I T C U R T S N I E C I V R E S S S A P I ...

Page 2: ...ear 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...

Page 3: ...pper 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 10183...

Page 4: ...01840 10 1 1 Third Pass Flueway Baffle 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 Ca...

Page 5: ...nual Authorities having jurisdiction should be consulted before installations are made In all cases reference should be made to the following Standards USA BOILERS A Current Edition of American National Standard ANSI NFPA 31 Installation of Oil Burning Equipment for recommended installation practices B Current Edition of National Fuel Gas Code NFPA 54 ANSI Z223 1 C Current Edition of American Nati...

Page 6: ...te unless a pressure relief valve is installed into the specified 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 flooring Do not install boiler on carpeting Do not operate on floors where heat affected material is b...

Page 7: ...injury or loss of life to vent safely and will contribute toward maintaining the boiler s efficiency 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 syst...

Page 8: ...4 Install Jacket Top and Side Panels 45 Install Burner Swing Door BSD 47 Install 2nd and 3rd Pass Flueway Baffles 49 Procedure to Close and Secure Burner Swing Door 50 Install Burner Adapter Plate and Mount Burner Burner Specific 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...

Page 9: ...ame Burners Tables XIVa XIVb and XIVc 74 SECTION VIII REPAIR PARTS Regional Office 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...

Page 10: ...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 ...

Page 11: ... 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 1...

Page 12: ...19 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 Suffix N indicates natural gas fired suffix P indicates LP ...

Page 13: ...al flue 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 From Jacket Left Side Panel Provide clearance per Table I Dimension B for burner swing ...

Page 14: ...iler foundation similar to the one shown in Figure 2 is recommended if the boiler room floor is weak or uneven or if a water condition exists 4 PROVIDE AIR SUPPLY AND 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 ou...

Page 15: ...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 flue 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 maintai...

Page 16: ... 1 If improper vent is suspected remove pipe at breeching and operate boiler This will determine if excessive down draft blocked or restricted flue etc is causing the problem 2 If using type shown in A above be sure cap is raised sufficiently above main pipe to allow flue 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 u...

Page 17: ... 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...

Page 18: ...rting 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 finger WARNING Sealant must be properly applied t...

Page 19: ...19 Figure 5 Manual or Hydraulic Draw up Section Assembly ...

Page 20: ...20 Figure 6 Vertical Bracing of Rear Section Figure 8 Inspection Pad Locations for Section Draw up Figure 7 Setting of Nipples ...

Page 21: ...ion holds assembly in place Repeat for lower assembly Refer to Figure 5 to verify proper arrangement Step n DRAW UP SECTION SLOWLY AND EVENLY When you start machined surfaces between adjoining sections should be approximately 3 8 to 1 2 apart The 7 nipple will pull harder than the 3 nipple If two 2 people are pulling simultaneously stop periodically to verify that gaps between adjoining sections a...

Page 22: ...plings nuts are required to span the distance On these larger sizes thread couplings on front rods to mid point of coupling halfway pull next rod forward to meet front coupling Hold front coupling not front rod while threading rear rod into coupling nut until it contacts front rod at mid point Repeat this process until both lower rods protrude through rear section legs In the following order place...

Page 23: ...oint Step c From the Hydraulic Draw up Kit locate and assemble one 1 set of draw up assemblies that each include x 23 lg threaded rod s coupling nut s if applicable the appropriate pressure plate washer and hex nut as shown in Figure 5 Insert one 1 assembly through each of the 3 and 4 NPT bosses on rear section until pressure plate is tight against the boss Locate and place the 8 dia pressure plat...

Page 24: ...lies Use a torque wrench adjusted for 20 ft lb of torque to tighten four 4 rear hex nuts In lieu of a torque wrench use a combination wrench to tighten nuts approximately turn beyond hand tight to set tension Excess length of draw up rods must not extend beyond front and rear section to ensure proper fit of jacket adjust accordingly Step h Release tension on hydraulic pumps and rams and remove C H...

Page 25: ...25 SECTION III BOILER ASSEMBLY INSTRUCTIONS Knockdown Boiler Figure 9 Installation of Common Parts to Block Assembly ...

Page 26: ...eft side of BSD by engaging keyway slot in loop over pocket key to lock position see Figure 11 Attach each hinge loop with one 1 7 16 split lock washer and one 1 7 16 14 x 1 1 2 lg cap screw secure hardware wrench tight Figure 11 Hinge Loop 5 For BSD right hand swing right side hinge a Repeat 4a thru 4d but install hinge set and hardware in reverse locations for right hand swing 6 Complete Burner ...

Page 27: ...stall Flue Collector Clean out Covers at this time Covers must be installed after Jacket Rear Panels are in place 9 Install 1 4 NPT brass plug into tapping located at 10 o clock position on flue outlet collar Wrench tighten plug but do not over tighten See Figure 9 10 Apply thread sealant and install 3 NPT pipe plug in lower tapping on front section Wrench tighten until water tight See Figure 9 11...

Page 28: ...28 Table VII Modular Return Water Mixing Tube RWMT RC ...

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

Page 30: ...d with vertical axis of rear section as shown in Figure 14 6 Thread upper and lower positioning plugs into 1 2 NPT tappings If necessary push forward or pull back on RWMT assembly and or rotate until pins on positioning plugs engage alignment holes in tube see Figure 13 Wrench both plugs until water tight 7 Install RWMT front support plug into 3 NPT tapping on upper front section boss a Looking th...

Page 31: ...ure 18b Detail A Hand tighten nuts make sure washers engage casting below washer retaining lugs as shown in Detail B Repeat for opposite side 9 Wrench tighten hex nuts on all channel assemblies making sure rods are fully seated in slotted openings 10 Locate and install lower front center section brackets to casting legs Brackets are universal and can be used on either side of block assembly Refer ...

Page 32: ...32 Figure 17a Front Center Section Horizontal Channel Assembly w Mounting Hardware Figure 17b Rear Section Horizontal Channel Assembly w Mounting Hardware ...

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

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

Page 35: ...th washer through cast hole in leg and slot in bracket Hand tighten one 1 5 8 washer and hex nut on bolt Do not wrench tighten at this time Repeat for bracket on opposite side 12 Locate and secure vertical side channels painted black to horizontal top channels and lower brackets Position side channel so pilot hole on channel face is located at the top see Figure 21 Engage flanges on vertical side ...

Page 36: ...a Starting at the rear and working to the front hold the first tie bar on a slight angle and pass the end through I opening in rear bracket as shown in Figure 22 Step b Lower the tie bar between brackets as shown in Figure 22 Step c Pull tie bar back and engage opposite end through I opening in front or center section bracket as shown in Figure 22 Step d Engage slotted end of hook over lip of I op...

Page 37: ...il brackets it s the proper size for that location a Rear Insulation Wrapper Starting at the rear drape rear wrapper over block assembly with supply manifold hole facing the rear as shown in Figure 23 Pull insulation under horizontal channel open slits and pull insulation around supply manifold and top brackets on each side Pull both sides of insulation back between vertical channel and rear casti...

Page 38: ...om the rear install primary junction box without extension piece to horizontal channel on the left side of supply manifold using two 2 8 x lg hex head sheet metal screws see Figure 24b Install secondary junction box with extension piece to horizontal channel on right side of supply manifold using two 2 8 x lg sheet metal screws Figure 24a Internal Wiring Harness Components Figure 24b Internal Wiri...

Page 39: ...es install chaseway channel extension s see Figure 24d Position channel extension under next horizontal rail secure bracket on extension to previously installed channel with two 2 8 x lg hex head sheet metal screws Torque these screws until tight Secure front of channel extension to next horizontal rail with two 2 8 x 2 lg sheet metal screws Based on block size repeat until chaseway extension has ...

Page 40: ... front opening in J box Center connectors in primary J box and secure harness to chaseway using nylon wire tie No 1 see Figure 24f Note If Sage Boiler Control SBC is to be used with boiler refer to installation section of Sage Boiler Control Instruction Manual located in Sage Boiler Control Parts Carton at this time Review installation section of SBC manual in its entirety and keep on hand during ...

Page 41: ...ecure to front frame channel rails based on burner swing door BSD hinge arrangement determined previously Harness can be secured to suit any of the following arrangements a BSD with left hand hinge arrangement harness exits left side of jacket front panel en route to control panel b BSD with left hand hinge arrangement harness exits right side of jacket front panel en route to control panel Boiler...

Page 42: ...8 section boilers are shipped with the internal harness length suitable for an 8 section boiler To modify harness for a 7 section cut nylon wire tie A for a 6 section cut A B for 5 section cut A B C and for a 4 section cut A B C D Refer to Table IX and Figure 25 b 9 thru 13 section boilers are shipped with the proper harness length suitable for a 13 section boiler For boiler sizes 9 thru 12 modify...

Page 43: ... Right 33 TCP w H 27 TIP w J 27 TIP w J 33 TCP w J 18 Section Left 33 TCP w J 33 TIP w J 27 TIP w J 33 TCP w H Right 33 TCP w H 27 TIP w J 33 TIP w J 33 TCP w J Panel Designations TCP w J Top Corner Panel w Joiner Bracket TCP w H Top Corner Panel w Holes TIP w J Top Intermediate Panel w Joiner Bracket F Locate Jacket Top Corner Panels packed in carton marked JC 2 Install Jacket Top Corner Panels p...

Page 44: ...ex head SMS Secure panel 2 to rear frame rails using two 2 8 x lg hex head SMS Step 6 Repeat same procedure as Steps 1 thru 5 to install outer top panels to right side frame rails Note Right side of boiler uses same panels as left side with a reverse pattern starting at the rear and working forward G Locate Front Panel Shipped in Jacket Carton marked JC 1 Position jacket front panel against front ...

Page 45: ... I Install two 2 clean out covers to openings at bottom of flue collector Locate four 4 5 16 flat washers and four 4 5 16 18 x 7 8 lg cap screws from hardware bag Thread one 1 washer and cap screw into left tapping on each opening Engage slot on clean out cover behind washer Thread second cap screw with washer through slot and into tapping on opposite end Wrench tighten hardware securely See Figur...

Page 46: ...ermediate Top Panel 20 1 4 Intermediate Top Panel 11 3 8 Rear Top Panel 13 Section 29 Front Top Panel 27 Intermediate Top Panel 27 Intermediate Top Panel 11 3 8 Rear Top Panel 14 Section 35 3 4 Front Top Panel 27 Intermediate Top Panel 27 Intermediate Top Panel 11 3 8 Rear Top Panel 15 Section 29 Front Top Panel 33 3 4 Intermediate Top Panel 33 3 4 Intermediate Top Panel 11 3 8 Rear Top Panel 16 S...

Page 47: ...ate top panel s and install in order of assembly shown in Table XI Position panel between outer top corner panes Slide forward to engage locking tabs into slotted openings on previously installed panel see Figure 30b Secure rear flange with two 2 8 x lg SMS Repeat until intermediate panels reach supply manifold Step 3 Position jacket rear top panel between outer top corner panels behind supply man...

Page 48: ... Long sleeved loose fitting clothing 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 airtight plastic bag RCF and crystalline silica are not clas...

Page 49: ...nough to move hinge pockets through opening in jacket front panel Engage hinge loop attached to door over hinge pin attached to block assembly Lower door to rest weight on hinge pin brackets M Locate Flueway Baffle Carton s marked 2FB and 3FB and remove contents Check Equipment Check List for proper baffle length and usage per boiler size 1 On 4 thru 11 Section Boilers Install four 4 third pass ba...

Page 50: ...ing tightening method from right side to left side cap screws to secure door until sealed without applying excessive torque Never tighten hardware on either side 100 without using the alternating tightening method Failure to follow the prescribed procedure could cause thread damage a crack in the casting or a leak in the door seal O Mount Burner Adapter Plate to Burner Swing Door refer to Figures ...

Page 51: ...Plate Boiler Model Part No I D No A B MPC4 thru MPC7 602263451 45 6 3 8 10 1 4 MPC8 thru MPC11 602263461 46 8 3 8 11 11 16 Power Flame JR Series Burner Adapter Plate Boiler Model Part No I D No A B MPC4 thru MPC7 602263001 00 6 3 4 10 MPC8 thru MPC15 602263011 01 8 1 4 10 MPC16 thru MPC18 602263021 02 10 1 4 11 Beckett CF Series Burner Adapter Plate Boiler Model Part No I D No A B MPC4 and MPC5 60...

Page 52: ...iate terminals per wiring diagram provided with burner Q Install Logo Plate on Jacket Front Panel if Optional Jacket Split Burner Swing Door Cover Panels are not to be used Locate Logo Plate shipped in Instruction Envelope Peel paper off adhesive strips and install by inserting positioning tabs on rear of Logo Plate into slotted openings located at top of front panel shown in Figure 37 If optional...

Page 53: ...n tapping D as shown in Figure 38 Wrench well until water tight 5 Locate L4006A Operating Control and remove knockout on casing closest to mounting hole Connect end of harness with forked terminals to casing knockout Connect wires to terminal on limit control wires are interchangeable Refer to Figure 39 6 Connect opposite end of L4006A Operating Control Harness to right side junction box cover A h...

Page 54: ...ver Install 7 8 knockout plugs provided to all unused holes refer to Figure 40 2 Install High Limit Control w Manual Reset L4006E a Apply thread sealant to 3 4 immersion well and install in Tapping F as shown in Figure 38 Wrench well until water tight b Locate L4006E High Limit Control and remove knockout on casing closest to mounting hole Connect end of harness with forked terminals to casing kno...

Page 55: ... harness to junction box cover A hole location 4 as shown in Figure 40 iv Locate mating connector labeled LO HI LO MOD inside right junction box Join mating connectors which are polarized and lock together Lightly tug on connectors to make sure they are secure v Proceed to next appropriate control option listed below for installation details If no other controls are being installed at this time se...

Page 56: ...ed washers Figure 46 Install Flue Outlet Damper Assembly 2 Assemble two cap screw washer combinations then insert cap screws washers through a flue outlet damper assembly mounting ring at 3 o clock and 9 o clock positions Place the flue outlet damper gasket onto cap screws and position damper with gasket onto boiler rear flue collector aligning screws with flue collector threaded holes 3 Thread th...

Page 57: ... A Pull down on left cover panel to lock hooks in slots and top flange behind hanger bracket 4 Install right side BSD cover panel using the same procedure used on left cover panel Before locking panel in place make sure right cover panel overlaps offset flange of left cover panel 5 Secure panels together at seam using six 6 8 x 1 2 lg hex head SMS one 1 screw on top and five 5 screws on the face a...

Page 58: ...cturer s warranty DO NOT improperly pipe boiler WARNING All hot water pipes must have clearances of at least 1 2 from all combustible construction WARNING A hot water boiler installed above radiation level must be provided with a low water cutoff device as part of the installation 1 HOT WATER HEATING This boiler must be installed in strict accordance to the instructions found in this installation ...

Page 59: ...ting Requirements 7 Diaphragm expansion tank shown but other types of air elimination systems may be used Boiler Model Supply Return 20 F Rise 40 F Rise Nom I D Inch Water Side Press Drop Ft Wtr Flow Rate GPM Nom I D Inch Water Side Press Drop Ft Wtr Flow Rate GPM MPC4 2 1 9 42 4 1 0 9 21 2 MPC5 2 2 6 65 2 1 1 6 32 6 MPC6 2 3 3 83 7 1 2 3 41 9 MPC7 2 4 0 102 3 1 3 0 51 2 MPC8 2 4 7 120 9 2 3 7 60 ...

Page 60: ...perature 80 F Maximum Delta T 80 F Minimum Supply Water Temperature 130 F Figure 49b Recommended MPC Minimum Piping Multiple Boiler Application NOTES For Boiler pipe sizes flow rates pressure drops and other important information and notes refer to Figure 49a ...

Page 61: ... 9 144 1 MPC18 4 11 7 306 6 3 10 6 153 3 1 2 Boiler Operating Requirements Minimum Return Water Temperature 80 F Maximum Delta T 80 F Minimum Supply Water Temperature 130 F NOTES 1 All piping is schedule 40 2 Pipe sizes listed are based on a 20 F or 40 F Delta T temperature rise across the boiler Select one to match application 3 When specified piping size is less than 4 install appropriate size r...

Page 62: ...mperature 80 F Maximum Delta T 80 F Minimum Supply Water Temperature 130 F Figure 50b Alternate MPC Minimum Piping Multiple Boiler Application NOTES For Boiler pipe sizes flow rates pressure drops and other important information and notes refer to Figure 50a ...

Page 63: ... Conversion c Alternate Piping Arrangements Piping arrangements other than Parallel and Primary Secondary such as System Bypass are acceptable as long as they ensure that the flow and temperature requirements of the boiler are met d Glycol Antifreeze Solutions Many systems today use ethylene or propylene glycol antifreeze solutions as a measure for freeze protection as well as a pump lubricator an...

Page 64: ...49b 50a and 50b for recommended indirect water heater piping NOTICE DO NOT use the boiler circulator as an indirect domestic hot water system circulator D Relief Valve Discharge Piping see Figure 54 Pipe discharge to within 4 of floor or to a suitable drain Do not reduce piping size or install shut off valve in discharge piping If discharge is weeping do not plug relief valve or cap discharge pipi...

Page 65: ... but add water slowly C SET CONTROLS with burner service switch turned OFF 1 PRESS RESET BUTTON on primary control and release 2 BOILER OPERATING AQUASTAT The operating aquastat L4006A should be set to the designed supply temperature typically 180 F 3 BOILER HIGH LIMIT AQUASTAT The high limit aquastat L4006E can be identified with a red manual reset button Ideally the high limit aquastat should be...

Page 66: ...ater can be discharged into local waste water system 1 Filling of Boiler and System General In a hot water heating system the boiler and entire system other than the expansion tank must be full of water for satisfactory operation Water should be added to the system until the boiler pressure gauge registers normal system design operating pressure To insure that the system is full water should come ...

Page 67: ...gh enough can corrode the cast iron through from the waterside Since neither of these failure types are the result of a casting defect the warranty does not apply Clearly it is in everyone s best interest to prevent this type of failure The maintenance of system integrity is the best method to achieve less makeup water H OXYGEN CORROSION WARNING Oxygen contamination of the boiler water will cause ...

Page 68: ...washers from the hinge pockets on the BSD d Open the BSD and remove the baffles from all flue passages e Use a wire or fiber bristle brush to remove any accumulated soot or debris from all of the flue baffles DANGER This boiler used flammable gas high voltage electricity moving parts and very hot water under high pressure Assure that all fuel and electric power supplies are off and that the water ...

Page 69: ... The rope gasket will provide sufficient seal when the door is snugged in place e Reinstall the burner to the BSD if removed and secure it in place on its support pedestal Inspect the burner gasket to assure an adequate seal Replace it if damaged f Connect the fuel lines g Reattach the BSD cover panels if provided CAUTION Do not start the burner unless BSD smokepipe flue clean out covers and burne...

Page 70: ... is used Check float for evidence of collapse and check mercury bulb where applicable for mercury separation or discoloration DO NOT ATTEMPT TO REPAIR MECHANISMS IN THE FIELD Complete replacement mechanisms including necessary gaskets and installation instructions are available from the manufacturer D Check burner and controls at least once a year See Section V Paragraph E under Operating Instruct...

Page 71: ... switch Make aural and visual check Check valve position indicators and fuel meters if so fitted Perform leakage tests Refer to burner instructions Combustion Safety Controls Flame Failure Flame Signal Strength Weekly Weekly Operator Operator Close manual fuel supply for 1 pilot 2 main fuel cock and or valve s Check safety shutdown timing Record in Log If flame signal meter installed read and log ...

Page 72: ...ctions Fuel Valve Interlock Switch Annually Service Technician Refer to burner instructions Purge Switch Annually Service Technician Refer to burner instructions Burner Position Interlock Annually Service Technician Refer to burner instructions Burner Rotary Cup Interlock Annually Service Technician Refer to burner instructions Low Fire Start Interlock Annually Service Technician Refer to burner i...

Page 73: ...00 CF114KR 8 29 68 265 265 Hago 8 00 X 45 P Table XIIIa Beckett 2 Oil Burner Specifications BOILER MODEL BURNER MIN INPUT MBH BURNER MAX INPUT MBH BURNER MODEL DAMPER SETTINGS MANIFOLD PRESSURE WC MINIMUM INLET PRESSURE WC LOW FIRE HIGH FIRE SHUTTER BAND LOW FIRE START HIGH FIRE MPC4 300 500 CG10 3 N A N A 6 0 1 0 1 8 2 80 MPC5 300 773 CG10 5 N A N A 10 0 1 6 3 2 4 80 MPC6 350 995 CG15 2 26 45 N A...

Page 74: ...PUT MBH BURNER MODEL DIFFUSER OPENING IN APPROX HIGH FIRE DAMPER SETTING TOP BOTTOM DAMPER IN APPROX NAT GAS MANIFOLD PRESS AT ORIFICE TEE WC MINIMUM NAT GAS INLET PRESS WC MPC4 300 500 JR15A 10 N A 1 2 1 2 4 0 MPC5 300 773 JR30A 12 N A 3 4 1 5 4 2 MPC6 300 995 JR30A 12 N A 13 16 2 5 4 9 MPC7 600 1216 JR30A 12 N A 1 3 32 3 5 5 6 MPC8 650 1438 JR50A 15 N A 3 4 2 0 5 9 MPC9 650 1660 JR50A 15 N A Wid...

Page 75: ... 2 6 5 9 MPC11 2103 15 0 C2 GO 20A 3 8 1 3 8 1 1 4 2 0 6 5 MPC12 2325 16 6 C2 GO 20A 3 8 1 3 4 1 3 4 2 4 5 7 MPC13 2547 18 2 C2 GO 20B 3 8 1 1 2 1 1 4 2 9 6 5 MPC14 2769 19 8 C2 GO 20B 1 2 1 1 4 1 1 4 3 0 6 5 MPC15 2991 21 5 C3 GO 20 1 2 1 7 8 Closed 1 7 5 6 MPC16 3213 23 0 C3 GO 20 5 16 1 3 4 1 3 4 2 3 6 9 MPC17 3435 24 5 C3 GO 20 3 8 2 2 2 6 6 6 MPC18 3657 26 0 C3 GO 20 3 8 Both Wide Open 2 5 6 ...

Page 76: ...Should you require assistance in locating a Burnham Commercial Cast Iron distributor in your area or have questions regarding the availability of Burnham Commercial Cast Iron products or repair parts please contact Burnham Commercial Cast Iron Customer Service at 888 791 3790 or Fax 877 501 5211 Figure 55 MPC Cast Iron Section Assembly ...

Page 77: ... Rope Gasket 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 101635 01 7 5 8 Dia x 164 Lg Pre cut Silicone Coated Perimeter Rope Gasket 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 101635 03 8 Tie Rods 8A 5 8 11 x 24 1 4 Lg 4 4 4 4 101753 01 8B 5 8 11 x 31 Lg 4 4 4 4 101754 01 8C 5 8 11 x 37 3 4 Lg 4 4 4 101755 01 8D 5 8 11 x 45 1 2 Lg 4 4 4 4 101756 01 8E 5 8 11 x 27 Lg 4 4 4 4 4 8 80861022 8F 5 8 11 x 34 Lg 4 4 4...

Page 78: ...78 Figure 56 MPC Common Bare Boiler Components ...

Page 79: ...2 2 2 2 101634 01 10 5 16 Flat Washer USS Plated 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 80860611 11 5 16 18 x 7 8 Lg Hex Head Cap Screw Plated 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 80861371 12 BSD Hinge Latch Machined 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 100731 01 13 BSD Hinge Loop Machined 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 100732 01 14 7 16 Split Lock Washer Plated 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 101758 01 15 7...

Page 80: ...80 Figure 56 MPC Common Bare Boiler Components continued ...

Page 81: ... 3 8 Dia Hole 1 1 1 1 602263421 OR Gas Burner 22K Power Flame JR BAP No 45 6 3 8 Dia Hole 1 1 1 1 602263451 22L Power Flame JR BAP No 41 9 Dia Hole 1 1 1 1 602263411 23 Burner Adapter Plate Gasket RCF 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8022601 24 3 8 Split Lock Washer Plated 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 80860650 25 3 8 16 x 7 8 Lg Hex Head Cap Screw Plated 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 80861352 26 1 2...

Page 82: ...82 Figure 57 MPC Front Center Section Frame Rail Assembly ...

Page 83: ... OD x 7 16 ID x 17 32 Lg Spacer 4 4 4 8 8 8 8 8 12 12 12 12 12 20 20 101597 01 6 3 8 Flat Washer USS Plated 8 8 8 16 16 16 16 16 24 24 24 24 24 32 32 80860618 7 3 8 16 Serrated Flange Hex Nut Steel Plated 4 4 4 8 8 8 8 8 12 12 12 12 12 16 16 80860498 8 Jacket Frame Lower Front Center Bracket 2 2 2 4 4 4 4 4 6 6 6 6 6 8 8 100760 01 9 5 8 11 x 2 Lg Hex Head Bolt Plain 2 2 2 4 4 4 4 4 6 6 6 6 6 8 8 8...

Page 84: ...84 Figure 58 MPC Rear Section Frame Rail Assembly ...

Page 85: ... 21 32 Lg Spacer 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 101597 03 6 11 16 OD x 7 16 ID x 1 23 32 Lg Spacer 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 101597 02 7 3 8 Flat Washer USS Plated 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 80860618 8 3 8 16 Serrated Flange Hex Nut Steel Plated 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 80860498 9 Jacket Frame Lower Rear Bracket 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 100761 01 10 5 8 11 x 2 Lg Hex Head Bolt Plai...

Page 86: ...86 Figure 59 MPC Return Water Mixing Tube RC Assembly ...

Page 87: ...e End Total Tubes Required 102789 01 17 13 16 102790 01 18 100727 01 21 5 16 100727 02 28 1 16 102788 03 18 3 4 102788 01 22 1 8 102788 02 28 3 4 MPC4 1 1 2 MPC5 1 1 2 MPC6 1 1 1 3 MPC7 1 1 1 3 MPC8 1 1 1 3 MPC9 1 1 1 1 4 MPC10 1 1 1 1 4 MPC11 2 2 1 5 MPC12 1 2 1 4 MPC13 1 2 1 4 MPC14 1 1 2 1 5 MPC15 2 3 1 6 MPC16 3 3 1 7 MPC17 2 3 1 1 7 MPC18 2 3 1 1 7 ...

Page 88: ...88 Figure 60 MPC Heat Exchanger Insulation Wrapper ...

Page 89: ... 24 5 8 x 140 3 4 Lg 1 101849 01 2B 4 Thk Nominal x 31 3 8 x 140 3 4 Lg 1 1 1 1 1 1 1 101849 02 2C 4 Thk Nominal x 38 1 8 x 140 3 4 Lg 1 1 1 1 101849 03 3 Center Heat Exchanger Wrapper Insulation 3A 4 Thk Nominal x 27 x 140 3 4 Lg 1 1 2 1 101851 01 3B 4 Thk Nominal x 33 3 4 x 140 3 4 Lg 1 1 1 1 101851 02 4 Rear Heat Exchanger Wrapper Insulation 4A 4 Thk Nominal x 28 1 4 x 140 3 4 Lg 1 1 1 101850 0...

Page 90: ...90 Figure 61 MPC Internal Wiring Harness Components ...

Page 91: ...el Extension 5A 20 5 16 Lg 1 101519 01 5B 27 1 16 Lg 1 1 2 2 1 3 2 101519 02 5C 33 13 16 Lg 1 1 1 2 2 1 101519 03 6 8 x 2 1 2 Lg Type AB Slotted Hex Hd Washer Screw SM Steel Plated 4 4 4 6 6 6 6 6 8 8 8 8 8 10 10 101757 01 7 7 64 Push On Plastic Edge Trim Polyethylene Blk Cut Length 16 Lg 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 101846 01 8 Internal Wiring Harness Assembly 8A MPC4 Thru MPC8 1 1 1 1 1 101438 ...

Page 92: ...92 Figure 62 MPC Jacket Panel Assembly ...

Page 93: ...nk Sensor J Box Cover 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 101427 01 6 Jacket Outer Top Corner Panel Assembly with Short Long Brackets 6A 27 Lg 2 2 100765 01 6B 33 3 4 Lg 2 2 2 2 2 2 2 2 100765 02 6C 40 1 2 Lg 2 2 2 2 2 100765 03 7 Jacket Outer Top Intermediate Panel Assembly with Long Brackets 7A 27 1 16 Lg 2 2 4 2 100764 01 7B 33 13 16 Lg 2 2 2 2 100764 02 8 Jacket Outer Top Corner Panel Assembly with ...

Page 94: ...94 Figure 62 MPC Jacket Panel Assembly continued ...

Page 95: ...1767 03 14E 32 15 16 x 55 5 16 1 1 1 1 101767 04 14F 36 11 16 x 55 5 16 1 101767 05 15 Jacket Side Panels 15A 19 7 16 x 55 5 16 1 100746 01 15B 23 3 16 x 55 5 16 1 2 2 2 100746 02 15C 26 3 16 x 55 5 16 1 1 3 3 1 5 3 100746 03 15D 29 15 16 x 55 5 16 1 2 2 2 2 2 2 2 100746 04 15E 32 15 16 x 55 5 16 1 1 2 3 3 2 100746 05 15F 36 11 16 x 55 5 16 1 2 2 100746 06 16 Snap Bushing Heyco SB 1093 15 2166 Bla...

Page 96: ...96 Figure 63 MPC 2 nd and 3 rd Pass Flueway Baffles ...

Page 97: ... 1D 38 2P Baffle Assembly w Handles 4 101647 04 1E 45 2P Baffle Assembly w Handles 4 101647 05 1F 51 2P Baffle Assembly w Handles 4 101647 06 1G 58 2P Baffle Assembly w Handles 4 4 4 101647 07 1H 65 2P Baffle Assembly w Handles 4 4 101647 08 1J 72 2P Baffle Assembly w Handles 4 4 101647 09 1K 78 2P Baffle Assembly w Handles 4 4 101647 10 2 3 rd Pass Flueway Baffle Assembly w Handles 25 1 4 Lg Cold...

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

Page 99: ...01 40 Temperature Pressure Gauge 3 Dia NPT 0 100 PSI 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 8056028 50 Relief Valve 50 PSI 50A Conbraco 10 614 10 x 1 1 1 1 1 1 1 81660359 50B Conbraco 10 615 10 1 x 1 1 1 1 1 81660362 50C Conbraco 10 616 10 1 x 1 1 1 1 1 1 81660357 60 Street Elbow Black Malleable 60A x 90 1 1 1 1 1 1 806601501 60B 1 x 90 1 1 1 1 806601514 60C 1 x 90 1 1 1 1 1 806601516 70 Nipple SCH 40 Blac...

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

Page 101: ... 1 806601516 61D 1 x 90 1 1 806601517 71 Nipple SCH 40 Black 71A x 3 Lg 1 1 1 806600038 71B 1 x 4 Lg 1 1 1 806600026 71C 1 x 4 Lg 1 1 1 1 1 1 1 806600028 71D 1 x 4 Lg 1 1 806600016 81 Reducing Bushing Black Malleable 81A 1 x 1 1 1 806600507 81B 1 x 1 1 1 1 806600521 81C 1 x 1 1 1 1 1 1 1 1 806600539 52 Relief Valve 80 PSI 52A Conbraco 10 614 16 x 1 1 1 1 1 1 1 1 1 1 81660365 52B Conbraco 10 615 16...

Page 102: ...102 Figure 65 MPC Optional Controls ...

Page 103: ...01 3 Low Fire Hold Control 3A Limit Honeywell L4006B1189 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 80160656 3B Immersion Well Honeywell 123872A NPT x 3 Insulation 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 80160497 3C Wiring Harness LFH Control to J Box 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 101386 01 4 Low High Low Control 4A Limit Honeywell L4006A2015 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 80160400 4B Immersion Well Honeywell 123871A NPT...

Page 104: ...old Figure 15 30 Hand Form Support Channel Bracket Figure 16 31 Secure Bracket to Horizontal Channel Figure 17a 32 Front Center Section Horizontal Channel Assembly w Mounting Hardware Figure 17b 32 Rear Section Horizontal Channel Assembly w Mounting Hardware Figure 18a 33 Mount Rear Section Horizontal Channel to Block Assembly Figure 18b 33 Mount Rear Section Horizontal Channel to Block Assembly F...

Page 105: ...tappings in Supply Manifold Figure 39 53 Install Standard Trim and Operating Control Figure 40 53 Control Connections to Internal Wiring Harness Figure 41 54 Install Probe Low Water Cut Off Figure 42 54 Install High Limit Control Figure 43 55 Install Modulation Control Figure 44 55 Install Low High Low Control Figure 45 55 Install Modulation Control Figure 46 56 Install Flue Outlet Damper Assembly...

Page 106: ...86 MPC Return Water Mixing Tube RC Assembly Description 87 Return Water Mixing Tube RC Assembly Figure 60 88 MPC Heat Exchanger Insulation Wrapper Description 89 Heat Exchanger Insulation Wrapper Figure 61 90 MPC Internal Wiring Harness Components Description 91 Internal Wiring Harness Components Figure 62 92 94 MPC Jacket Panel Assembly Description 93 95 Jacket Panel Assembly Figure 63 96 MPC 2nd...

Page 107: ...odular Return Water Mixing Tube RWMT RC Table VIII 31 Frame Bracket Mounting Locations Table IX 41 Internal Wiring Harness Adjustment Table X 43 Jacket Top Corner Intermediate Panel Arrangement Table XI 46 Jacket Top Panel Arrangement Section IV Installation Instructions Section V Operating Instructions Section VI Service Instructions Table XII 71 72 Recommended Periodic Testing Check List Section...

Page 108: ...nsatisfactory performance as a result of faulty workmanship in the installation which liability is expressly disclaimed e Boilers parts or accessories installed outside the 48 contiguous United States the State of Alaska and Canada f Damage to the boiler and or property due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instruction m...

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