Burnham FM01FD00B - Manuals

7 WARNING Appliance materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cau...

8 TABLE OF CONTENTS SECTION I - GENERAL INFORMATION Dimensional Information ................................................................................................................. 10 Ratings/Data .................................................................................................

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.

11 SECTION I - GENERAL INFORMA TION Boiler Model Number of Sections Dim. A (Inches) * Burner Dimension B (Inches) Minimum Flue Baffle Installation Clearance Dim. C (Inches) V ent (Flue Outlet Damper) Connection Size Dim. D (Inches) Approx. W eight of Sections - LBS. (Block Assy .) Approx. Shipping W...

1 Model MPC™ Boilers Boiler Model Boiler Horsepower Burner Input Gross Output (MBH) Net I=B=R Rating (MBH) Combustion Efficiency Heating Surface (Sq. Ft.) Net Furnace V olume (Cu. Ft.) Pressure in Firebox (Inches Wtr . Column) W ater Content (Gallons) Boiler W eight w/W ater (LBS.) V ent (Flue Outle...

1 SECTION I - GENERAL INFORMATION (Continued) A. INSPECT SHIPMENT carefully for any signs of damage. 1. ALL EQUIPMENT is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of crated Boiler to the carrier in good condition. 2. ANY CLAIMS for damage or shortage in sh...

1 Table V: Minimum Installation Clearances To Combustible Materials (Inches) per UL76 (Packaged / Firetested Boiler) C A B Chimney D E F Boiler Above Front Connector Rear Sides Below MPC 18 48 18 18 18 NC * * NC - Noncombustible Flooring Note: See Table III for recommended service clearance to acces...

15 a. In the absence of local requirements, the confined space shall be provided with two permanent openings, one in or near the top of the room and one near the bottom. The openings shall communicate by means of ducts, with the outdoors or to such spaces (crawl or attic) that communicate with the o...

16 Figure b: Vents - Faults and Suggestions WARNING Venting Instructions are recommendations only. Consult a venting expert on the design of a specific vent system for your application. The ASHRAE Venting Guide and The National Fuel Gas Code, NFPA 5 should be considered in all venting systems. Conve...

17 A. FACTORY ASSEMBLED SECTIONS - The assemblage should be set in the proper location as outlined in Section I. Lifting arrangement and weights are given in Figures 4a and 4b. Figure a: Lifting Instructions - Limited to thru 1 Section Block Assembly (No Steel Base) Figure b: Lifting Instructions - ...

1 WARNING This is a forced draft fired boiler and sealant must be applied where specified for proper and safe performance. Burnham Commercial has approved section joint sealants (silastics) manufactured by Dow-Corning under the product number RTV 76, and Sil-Bond under the product number RTV 6500. W...

adjacent sections as the boiler operates with a positive pressure in the firebox and products of combustion will escape between sections unless they are properly sealed. The rope and sealant should be applied before each section is placed on the assembly. NOTICE As assembled length increases, use /”...

2. ASSEMBLY OF SECTIONS (hYDRAULic DRAW-UP) • MPC4 through MPC12 Section Assemblies The entire assemblage may be drawn-up at one time using the hydraulic draw-up equipment providing the operation is completed within two (2) hours after the sealant was applied to the first casting in the assembly. If...

step f. After all sections have been drawn up, retention rods must be installed. Do not release hydraulic pressure until the retention rods are in place. step g. Locate the threaded 5/8” retention rods, washers, tension springs and nuts supplied in ‘BAC’ Boiler Assembly Carton. Assemble both top ret...

5 SECTION III - BOILER ASSEMBL Y INSTRUCTIONS (Knockdown Boiler) Figure 9: Installation of Common Parts to Block Assembly

6 A. 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. burner swing door (BSD) hinge/latch castings, two (2) C. I. BSD hinge loop castings, ten (10) 7/16 split lock washers and ten (10) 7/16 -14 x 1-1/2 lg. c...

7 f. Install observation port sight glass. Locate 2” x 2-1/2” lg. nipple, sight glass envelope and 2” conduit bushing. Thread 2” nipple into observation port tapping directly above burner adapter opening on front of BSD. Open sight glass envelope and in this order place gasket, sight glass and gaske...

0 Repeat 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 13 for details. If space behind the boiler is limited, on RWMT’s having two or more tubes, it may be necessary to assemble the end cap to the adjoinin...

1 5. Add front/center section mounting hardware to all but one (1) horizontal support channel assembly. Lay channel assembly on floor with brackets facing up, see Figure 17a. Install hardware as shown with two (2) washers and two (2) 1/2” lg. spacers between bracket legs and one (1) washer and one (...

Figure 19: Attachment of Lower Front/Center Section Bracket to Casting Leg Figure 0: Attachment of Lower Rear Section Bracket to Casting Leg

5 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. Locate and install rear section brackets to casting legs. Brackets are universal and can be used on either side of block assembly. Brackets mount to front...

6 Figure : Lower Tie Bar Installation Repeat operation until all vertical channels have been installed. Using an open end wrench and ratchet with socket, tighten all 5/8” bolts and nuts to secure frame brackets to casting legs. 13. Locate Jacket Carton(s), marked ‘JC-2’ and remove contents. Install ...

7 D. Locate and Install Heat Exchanger (Block Assembly) Insulation Wrapper(s), see Figure 23. 1. 4 thru 6 section Block Assembly - Insulation wrapper is provided as one-piece that covers block from front to rear. Drape insulation wrapper over block assembly with supply manifold hole to the rear. Sta...

9 3. 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. Install the end with 8¼” lg. side flange under horizontal rail and through openings in junction box until end protrudes past rear horizontal channel. ...

1 Figure g: Internal Wiring Harness Components - Secure Harness to Vertical Channel Insert first set of harness connectors through opening in rear of secondary junction box. Remove excess slack between J-boxes until protective sleeve is centered on raw edge of channel extension, secure harness to ch...

Table X: Jacket Top Corner / Intermediate Panel Arrangement Boiler Size Side of Boiler Order of Assembly (* See Panel Designation Below) Front f Block Assembly g Rear 4 Section Left 27” TCP w/J 6¾” TCP w/H Right 6¾” TCP w/H 27” TCP w/J 5 Section Left 33¾” TCP w/J 6¾” TCP w/H Right 6¾” TCP w/H 33¾” T...

step 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” lg. hex head SMS per joint. Align mounting holes in panel(s) #3 with holes in frame rails and secure with two (2) #8 x ½” lg. hex head SMS per rail. Loca...

5 Figure 8: Jacket Split Rear Panel Detail Figure 9: Install Jacket Split Rear Panel h. Locate Jacket Split Rear Panel shipped in JC-1 Jacket Carton. Note: Before installing rear panel, drain valve and indirect water heater return piping (furnished by others) should be installed now due to accessibi...

6 step 1. Position front panel at approximately 30° angle, hook front flange under clips on outer top corner panels as shown in Figure 30a, Detail A, Step 1. Lower rear of panel into position between outer Boiler Size Order of Assembly Front f Block Assembly g Rear 4 Section 22-1/4” Front Top Panel ...

7 L. 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, perpendicular to front of boiler (full open position). Figure 1: Install Burner Swing Door Figure 0b: Install Jacket Top Panels - Viewed From Rear Figur...

8 Important Product Safety Information Refractory Ceramic Fiber Product Warning : The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures about 1805°F, such as during direct flame contac...

9 Figure : Install nd Pass Flueway Baffles Figure : Install rd Pass Flueway Baffles (4 thru 11 Section Boilers Only) 2. On 4 thru 18 Section Boilers - Install four (4) second pass baffles into second pass flueways until handle is flush with face of casting as shown in Figure 33, Detail A. Lift door ...

50 N. Close Burner Swing Door and secure using (4) 5/8” flat washers, (4) 9/16” lock washers and (4) 9/16 - 12 x 2” lg. cap screws as shown in Figure 34. There are (4) points of internal contact around perimeter of BSD and Front Section. These stop the door travel when tightening hardware to prevent...

51 1. In most cases the burner adapter plate carton for the specified burner will be provided by Burnham. 2. If adapter is provided by Burnham, open carton and remove contents. Apply four (4) small dabs of silastic on rear surface of adapter plate to temporarily hold gasket in place. Hold adapter pl...

5 1. 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 encased in flexible conduit from cover plate to burner control panel or junction box. 3. Locate front panel cover plates in JC-1 carton. 4. Determine r...

5 Note: Supply manifold must be installed with 1½” couplings aligned with front and rear axis of boiler. 2. Apply thread sealant and install temperature/ pressure gauge into tapping ‘G’, see Figures 38 and 39. Wrench until water tight. Tighten gauge using hex on stem, do not tighten or apply pressur...

5 s. 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 and install in Tapping ‘E’, see Figure 38. Wrench hex until water tight. b. Remove 2 nd knockout from bottom of M&M 750P LWCO control case. Connect...

55 c. 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. Locate mating connector labeled “Low Fire Hold” inside right junction box. Join mating connectors which are polarized and lock together. Lightly tug on ...

56 v. Connect opposite end of T991A Modulating Control harness to right side junction box cover ‘A’, hole location #4 as shown in Figure 40. vi. Locate mating connector labeled “LO-HI- LO/MOD” inside right junction box, see Figure 40. Join mating connectors which are polarized and lock together. Lig...

58 SECTION IV - INSTALLATION INSTRUCTIONS Packaged Boiler Shipping Information Figure 8: Packaged Boiler Shipping Information A. PAcKAGED BOiLER 1. The packaged boiler comes on its own shipping skid (see Figure 48) and the assembled block is hydrostatically tested at the factory. Once the boiler is ...

59 Figure 9a: Recommended MPC Minimum Piping - Single Boiler Application 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 supply/return piping size is less than 4”, i...

61 Figure 50a: Alternate MPC Minimum Piping - Single Boiler Application 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 1½ 0.9 21.2 MPC5 2 2.6 65.2 1½ 1....

6 a. Temperature and Flow Requirements – An existing parallel piping system may be used, provided the return water is not below 80°F and the return water temperature is not more than 80°F less than the boiler outlet temperature. A flow analysis should be performed to determine the flow through the b...

6 c. BOiLER PiPiNG, DOMEsTic hOT WATER (DhW) APPLicATiON – The MPC boiler can be used in many different piping applications to produce Domestic Hot Water (DHW). In some applications, depending on the control strategy (outdoor reset, setpoint operation, etc.) and size of the boiler, it is recommended...

65 SECTION V - OPERATING INSTRUCTIONS A. ALWAYs iNsPEcT iNsTALLATiON BEfORE sTARTiNG BURNER. B. fiLL hEATiNG sYsTEM WiTh WATER. 1. CLEAN HEATING SYSTEM IF boiler water is dirty. Refer to step (F) for proper cleaning instructions for water boilers. Fill entire Heating System with water and vent air f...

66 E. TEsT cONTROLs WARNING Before installation of the boiler is considered complete, the operation of the boiler controls should be checked, particularly the low water cutoff and the high limit control. 1. CHECK OPERATING CONTROL OPERATION. Raise and lower operating control setting as required to s...

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 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 p...

68 SECTION VI - SERVICE INSTRUCTIONS IMPORTANT - See Section V, Item (G) under Operating Instructions, if it becomes necessary to add water to the boiler more frequently than once a month. A. GENERAL - Inspection should be conducted annually. Service as frequently as specified in following paragraph...

69 f. Use a wire or fiber bristle brush of appropriate length and diameter to allow sufficient cleaning of all flue passages. Using long strokes, push the brush the whole way through the boiler and then pull it out. Repeat this process until all surfaces of each of the flue passages have been cleare...

70 WARNING Exercise caution when handling phosphoric acid and follow the instructions on container label. Always use protective clothing and equipment when working with/near chemicals. i. Wire brushing of the probe is not recommended as the soft platinum guard ring sandwiched between the ceramic ins...

71 Table XII: Recommended Periodic Testing Check List Item Frequency Accomplished by Remarks Gauges and Indicators Daily Operator Make visual inspection and record readings in log Instrument and Equipment Settings Daily Operator Make visual check against recommended specifications Firing Rate Contro...

7 Table XII: Recommended Periodic Testing Check List (continued) Item Frequency Accomplished by Remarks High Limit Safety Control Annually Service Technician Refer to instructions Operating Control Annually Service Technician Refer to instructions Low Draft, Fan, Air Pressure, and Damper Position In...

7 SECTION VII - BURNER SPECIFICATIONS BOILER MODEL BURNER MIN. INPUT (GPH) BURNER MAX. INPUT (GPH) BURNER MODEL AIR TUBE COMB. BURNER SETTINGS PUMP PRESSURE (PSI) NOZZLE MAKE NOZZLE DATA HEAD LOW FIRE AIR OR SHUTTER HIGH FIRE AIR OR BAND LOW FIRE HIGH FIRE GPH X ANGLE - TYPE MPC4 1.75 3.55 CF500 CF6...

76 SECTION VIII - REPAIR PARTS All MPC™ Repair Parts may be obtained through your local Burnham Commercial Cast Iron Wholesale distributor. Should you require assistance in locating a Burnham Commercial Cast Iron distributor in your area, or have questions regarding the availability of Burnham Comme...

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 ...

87 REP AIR P ARTS - RETURN W A TER MIXING TUBE RC ASSEMBL Y Boiler Model Return W ater Mixing T ube Assembly , Flared Collar Return W ater Mixing T ube Assembly , Square End T otal T ubes Required 102789-01 (17-13/16) 102790-01 (18) 100727-01 (21-5/16) 100727-02 (28-1/16) 102788-03 (18-3/4) 102788-0...

97 Item No. Description Boiler Sections / Quantity Part No. 04 05 06 07 08 09 10 1 1 12 13 14 15 16 17 18 1 2 nd Pass Flueway Baffles, 304 Stainless Steel: 1A. 18” 2P Baffle Assembly w/Handles 4 101647-01 1B. 24¾” 2P Baffle Assembly w/Handles 4 101647-02 1C. 31½” 2P Baffle Assembly w/Handles 4 10164...

10 Appendix A - figures Figure Number Page Number Description Equipment Check List Figure 1a 2 Carton Identification Section I - General Information Figure 1b 10 Dimensional Information Figure 2 14 Boiler Foundation Figure 3a 15 MPC With Rear Outlet Vent Figure 3b 16 Vents - Faults and Suggestions S...

105 Figure Number Page Number Description Section III - Boiler Assembly Instructions (Knockdown Boiler) (continued) Figure 25 42 Internal Wiring Harness - Length Adjustment for Penetration Through Side of Jacket Front Panel Figure 26 44 Install Top Corner/Intermediate Panels Figure 27 44 Install Jac...

106 Figure Number Page Number Description Section VIII - Repair Parts Figure 55 76 MPC Cast Iron Section Assembly Description 77 Cast Iron Section Assembly Figure 56 78 MPC Common Bare Boiler Components Description 79 Common Bare Boiler Components Figure 56 80 MPC Common Bare Boiler Components (cont...

107 Appendix B - Tables Table Number Page Number Description Section I - General Information Table I 11 Dimensional Information Table II 12 Ratings/Data Table III 13 Recommended Rear Service Clearance Table IV 13 Minimum Installation Clearances to Combustible Materials Table V 14 Boiler Foundation S...

108 Subject to the terms and conditions set forth below, Burnham Commercial, Lancaster, Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water or steam boiler or Burnham Commercial supplied parts and/or accessories manufactured and shipped on o...