INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR MPO - IQ™ 3-PASS OIL BOILER 9700609 9700609 As an ENERGY STAR® Partner, U.S. Boiler Company has determined that the MPO-IQ™ boiler meets the ENERGY STAR® guidelines for energy efficiency established by the United States Environmental Protection Agency (EPA). For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
IMPORTANT INFORMATION - READ CAREFULLY All boilers must be installed in accordance with National, State and Local Plumbing, Heating and Electrical Codes and the regulations of the serving utilities. These Codes and Regulations may differ from this instruction manual. Authorities having jurisdiction should be consulted before installations are made. In all cases, reference should be made to the following Standards: A. B. C. D.
DANGER DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Failure to follow all instructions in the proper order can cause personal injury or death.
WARNING This boiler must be properly vented. The chimney must be inspected for any obstructions and cleaned prior to each heating season. A clean and unobstructed chimney flue is necessary to produce the minimum draft required to safely evacuate noxious fumes that could cause personal injury or loss of life. Evidence of loose debris and or condensate induced stains at the base of the chimney flue, connector or smokepipe joints may be signs of condensing flue gases.
Congratulations on your purchase of a new MPO-IQ™ boiler—designed and constructed to provide you with years of reliable service. • ENERGY STAR™ efficiency – friendly on the environment and your wallet. • Cast iron heat exchanger – for reliability and durability, nothing beats a cast iron heat exchanger. • *IQ Control™ System– the most advanced and easiest to use controls available. • System-friendly – built-in protection from condensation and thermal shock.
Figure 1: MPO-IQ84 Thru MPO-IQ231 Water Boiler
28-5/8” 34-5/8” MPO-IQ189 MPO-IQ231 36” 30” 24” 7” 6” 6” 5” 5” “C” 17.84 14.46 11.08 7.70 7.70 Water Content - Gallons 0.80 1.05 1.35 1.65 MPO-IQ115 MPO-IQ147 MPO-IQI89 MPO-IQ231 231 189 147 115 84 MBH (1) 203 167 129 101 74 DOE Heating Capacity MBH (2) 177 145 112 87 64 Water MBH (3) NET AHRI Ratings 87 87 87 87 87 Water Boiler AFUE % 7 7 6 6 6 8x8 8x8 8x8 8x8 8x8 15 15 15 15 15 Round Rectangle Height In. Dia. In. x In. Ft.
I. PRE-INSTALLATION A. INSPECT damage. SHIPMENT carefully for any signs of 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 shipment must be filed immediately against the carrier by the consignee. No claims for variances from, or shortage in orders, will be allowed by the manufacturer unless presented within sixty (60) days after receipt of goods. B.
I. PRE-INSTALLATION (continued) C. PROVIDE COMBUSTION AND VENTILATION AIR. Local and National Codes may apply and should be referenced. WARNING Adequate combustion and ventilation air must be provided to assure proper combustion and to maintain safe ambient air temperatures. Do not install boiler where gasoline or other flammable vapors or liquids, or sources of hydrocarbons (i.e. bleaches, fabric softeners, etc.) are used or stored. 1. Determine volume of space (boiler room).
I. PRE-INSTALLATION (continued) 6. Louvers and Grilles of Ventilation Ducts a. All outside openings should be screened and louvered. Screens used should not be smaller than 1/4 inch mesh. Louvers will prevent the entrance of rain and snow. b. Free area requirements need to consider the blocking effect of louvers, grilles, or screens protecting the openings.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS A. REMOVE CRATE. 1. Remove all fasteners at crate skid. 2. Lift outside container and remove all other inside protective spacers and bracing. Remove miscellaneous parts carton. B. REMOVE BOILER FROM SKID. 1. To reduce the risk of damage to boiler jacket, use the following procedure to remove from skid, see Figure 3: Step 1. Boiler is secured to base with (4) 5/16" cap screws, (2) in front and (2) in rear of shipping skid, see Figure 3.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd) Figure 4A: Partial Front View - Burner Swing Door Mounted to Boiler - Fully Closed and Secured Step 4. Disconnect burner power cord from receptacle located in lower right corner of jacket front panel. Step 5. Door can be swung to the fully open position, approximately 90° to 120°, with the burner mounted providing that there is 19" of clearance to the adjacent wall, see Figures 1 and 4B.
II.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd) Step 2. If necessary, place your right hand under the burner air tube to lift upward. Lift the door up unto the built-in cast ramp/door rest (protruding from the bottom of the front section casting - see Figure 4A). E. INSPECT SWING DOOR INSULATION AND ROPE GASKET. 1. Open burner swing door using procedure previously outlined in Paragraph D of this section. Step 3.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd) Figure 4D: Burner Swing Door Insulation 1. Install return injector piping and relief valve, refer to Figure 5. Step a. Locate the return pipe fittings and injector. Apply sealant to the 2” NPT injector threads. Insert injector into 2” NPT upper rear tapping on rear section. Thread 2” NPT x 1-1/2” Reducing Elbow onto 2” NPT injector. Apply thread sealant to the 1-1/2” NPT nipple. Thread 1-1/2” NPT nipple into 1-1/2” NPT end of reducing elbow.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd) Figure 6: Piping Arrangement for Drain Valve and Indirect Water Heating Return 1-1/2" NPT horizontal left or right side return piping - Install relief valve vertically in 3/4" NPT tapping on tee. See Figure 5. Step c. Apply sealant to 3/4" NPT thread on drain valve. Thread into 3/4" NPT tapping on side outlet of tee. Use hex nut portion to tighten valve until water tight. Step c. Pipe discharge of relief valve as shown in Figures 13A and 13B.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd) WARNING Wire an additional safety limit such as a low water cut-off or temperature limit device, other than an IQ Control device, in series with the 120V circuit used to power the boiler. Do Not alter the boiler's factory wiring when adding additional limit. 4. Installing Boiler-ECOM harness (only used with Honeywell Oil Primary). Step a. Locate the black Cat5 harness in the miscellaneous parts carton. Step b.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd) Figure 8: Baffle Orientation in Flueways Step a. Install stainless steel baffles provided in miscellaneous parts carton as follows, refer to Table 3 and Figure 8: • • 18 Model MPO-IQ84 - To install flueway baffle in 3rd pass on left side of boiler, hold baffle with word "Left" readable at the top. Slide baffle in flueway until position tab touches fins on left side of 3rd pass flueway.
II. PACKAGED BOILER ASSEMBLY - TRIM & CONTROLS (cont'd) Figure 9: Oil Burner Installation (Beckett shown) 7. Install oil burner. (See Figure 9) Step a. Open burner carton and remove contents. Step b. Place oil burner gasket on burner and align holes. CAUTION Do not install burner without gasket. Step c. Remove three (3) 5/16-18 x 3/4 lg. cap screw from burner swing door used for mounting burner. Step d. Thread (1) 5/16-18 x 3/4 lg.
III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS MPO-IQ Unit-Pak Boiler Assembly Shipment (-LLU) Content Check List (see Figure 10) 1. ___ Cast Iron Section/Burner Swing Door/Smoke Box Assembly Mounted on Shipping Skid: ____ MPO-IQ84/115 – Part # 103071-02 / 100045-01 / 100021-01 ____ MPO-IQ147 – Part # 103071-03 / 100045-01 / 100021-01 ____ MPO-IQ189 – Part # 103071-04 / 100045-01 / 100021-01 ____ MPO-IQ231 – Part # 1030711-05 / 100045-02 / 100021-01 2.
III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued) A. Removal of Cast Iron Section/Burner Swing Door / Smoke Box Assembly from Skid. rear legs, until wooden block(s) can be removed (see Figure 11). Slowly allow the weight of boiler to tilt backward until rear legs rest on floor. WARNING 14. If wood blocks were placed under front legs, lift pipe handles; remove the blocks and lower front legs to floor. Remove pipe handles.
Figure 11: Boiler Removal from Skid III.
III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued) front section right side. These four front section bosses are front jacket panel and door mounting bracket attachment points. 2. Open Jacket Carton and locate jacket front panel (has factory attached 1” fiberglass insulation). See also “Repair Parts” Section, “Jacket Assembly” illustration for part identification. 3. Locate Hardware Bag, remove two 5/16”-18 x ½” Phillips pan head machine screws. 4.
III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued) 5. Position left Cleanout Cover over rear section cleanout opening, align section boss holes with Cleanout Cover holes, install both 5/16”-18 – 7/8” hex head cap screws hand tight, then, alternately tighten them with open end or socket wrench. 6. Repeat above steps with right Cleanout Cover. 7. Apply the adhesive sealant to the underside of the collar, all around, at the inside corner of the collar outer ring.
III. UNIT-PAK BOILER ASSEMBLY - TRIM & CONTROLS (continued) 11. Locate the Jacket Front Cover from Control Carton. See also "Repair Parts" Section, "Jacket Assembly" illustration for parts identification. N. FIELD ASSEMBLY OF BOILER TRIM AND BURNERS. Refer to Section II, Paragraph F. 12. Align jacket front cover mounting holes with side panel holes and secure with four #8 x ½" oval sheet metal screws from Hardware Bag.
IV. WATER Boiler PIPING NOTICE Failure to pipe boiler as specified in this manual may result in excessive system noise. A. E V A L U A T E SYSTEM. THE EXISTING WATER Design a piping system and install boiler which will prevent oxygen contamination of boiler water and frequent water additions. 1. There are many possible causes of oxygen contamination such as: a. Addition of excessive make-up water as a result of system leaks. b. Absorption through open tanks and fittings. c.
Figure 13A: Recommended Water Piping for Circulator Zoned Heating Systems IV.
Figure 13B: Recommended Water Piping for Zone Valve Zoned Heating Systems IV.
IV. WATER Boiler PIPING (continued) 5. See Figure 14 for suggested near boiler piping of Option Card Controls. WARNING The use of a low water cut-off device, while not required unless radiation level is below the boiler, is highly recommended. If a low water cut-off is required, it must be mounted in the supply piping above the boiler (see Figure 14).
V. NATURAL DRAFT VENTING (All Boiler Models) WARNING Vent this boiler according to these supplemental instructions. Failure to do so may cause products of combustion to enter the home resulting in severe property damage, personal injury or death. Insufficient Combustion Air Supply may result in the production and release of deadly carbon monoxide (CO) into the home which can cause severe personal injury or death.
V.
V. NATURAL DRAFT VENTING (continued) B. Chimney Connector 1. A chimney connector (vent pipe) is used to connect the boiler to the base of the chimney. The chimney connector should be kept as short as possible. The horizontal length of the chimney connector shall not be greater than 10 feet. NOTE: Secure chimney connector to cast iron smokebox collar with three (3) #10 x ½" self drilling hex head TEK screws provided in miscellaneous parts carton.
V. NATURAL DRAFT VENTING (continued) CAUTION Any doubt on the condition of a chimney or it’s ability to prevent the generation and accumulation of flue gas condensate, must be relined according to NFPA 31 (United States) or CSA B139 (Canada). CAUTION Use the chimney venting tables as a guide. It is highly recommended that any borderline application should result in the relining of the chimney with a suitable liner that creates sufficient draft and to protect against corrosion caused by flue gas condensate.
VI. direct venting / air intake piping (Boiler Models MPO-IQ147 thru 231 ONLY) A. GENERAL GUIDELINES 1. Direct Vent system must be installed in accordance with these instructions and applicable provisions of local building codes. Contact your local fire and building officials on specific requirements for restrictions and the installation of fuel oil burning equipment.
VI. direct venting / air intake piping (continued) e. Not less than 3 ft (as measured to side of vent termination) from an inside corner of an L-shaped structure. f. Not less than 1 ft from the nearest surface of the terminal to a roof soffit. g. Not directly above, or, not less than 5 ft horizontally from an oil tank vent. h. Not less than 2 ft from nearest surface of terminal to an adjacent building. Table 5: Wall cutout dimensions Boiler Model No. Direct Vent Conversion Kit Part No.
VI. direct venting / air intake piping (continued) D. Installing the Flex Oil Vent Pipe from the Vent Termination to the Boiler Flue Outlet 1. The venting system (vent pipe and all connectors) shall be installed in accordance with the applicable provisions of any local codes, and, in United States, requirements of NFPA 31- Standard for the Installation of Oil-Burning Equipment and NFPA211- Standard for Chimney, Fireplaces, Vents and Solid Fuel-Burning Appliances, latest editions.
VI. direct venting / air intake piping (continued) Table 6: Flex vent / vent termination pipe diameters Boiler Model No. MPO-IQ147 MPO-IQ189 MPO-IQ231 Boiler Flue Outlet Collar OD (Inch) Vent Hood Inner Pipe Diameter (Inch) Flex Oil Vent Pipe Inner Pipe Diameter (Inch) * Flue Outlet Collar to Vent Pipe Adapter (Inch) 6 5 6 to 5 7 6 7 to 6 NOTE: * The model specific Direct Vent (FDVS) Kit Cartons contain adapters (reducers) (see Table 6) to connect boiler flue outlet collar to vent pipe.
VI. direct venting / air intake piping (continued) Figure 25: Vent Pipe Ends, Vent Termination and Appliance Adapter Sealing F. Connecting Flex OilVent Pipe toAppliance Adapter and Direct Vent Termination 1. Flexible double wall oil vent pipe is available pre-cut from 5 ft to 20 ft long. If necessary, the vent pipe may be cut to required length with a hacksaw or cutoff saw. CAUTION Use safety glasses and other appropriated safety gear when cutting the vent pipe. 2.
VI. direct venting / air intake piping (continued) 2. Maximum air intake pipe length is 40 equivalent feet. WARNING DO NOT reduce size of air intake pipe. 3. Start at burner and work towards Direct Vent termination air intake. 4. Remove burner cover. Loosen two screws securing outside air duct bracket to burner cover mounting plate. See Figure 27. 5. Procure a 2-ft section of 4" diameter galvanized single wall vent pipe, cut off the crimped pipe end below stop bead. 6.
VI. direct venting / air intake piping (continued) 12. Assemble the vacuum relief valve balance weight onto the gate. Refer to the vacuum relief valve manufacturer’s instructions for details. 13. Mount the assembled vacuum relief valve gate with balance weight into the tee and fasten with a screw and nut in collar tabs. To insure proper operation, the gate must be level across the pivot point and plumb. Refer to the vacuum relief valve manufacturer’s instructions for details. 14.
VII. ELECTRICAL DANGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock once power is turned off. WARNING Failure to properly wire electrical connections to the boiler may result in serious physical harm. Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.
Figure 28A: Schematic Wiring Diagram VII.
Figure 28B: Schematic Wiring Diagram, All Burner Options VII.
VII.
VIII. OIL PIPING A. General 1. Use flexible oil line(s) so the burner swing door can be opened without disconnecting the oil supply piping. 2. A supply line fuel oil filter is recommended as a minimum for all firing rates but a pleated paper fuel oil filter is recommended for the firing rates below 1.0 GPH to prevent nozzle fouling. NOTICE Do not use compression fittings. Oil piping must be absolutely airtight or leaks or loss of prime may result. Bleed line and fuel unit completely.
VIII. OIL PIPING (continued) C. Two Pipe Oil Lines 1. For two piped systems, where more lift is required, the two-stage fuel unit is recommended. Table 7 (two-stage) and Table 8 (single-stage) show allowable lift and lengths of 3/8 inch and 1/2 inch OD tubing for both suction and return lines. Refer to Figure 30. 2. Follow the oil pump manufacturer’s recommendations on the proper connections for a two pipe system. Some manufacturers require the insertion of a bypass plug.
IX. SYSTEM START-UP WARNING All boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Be sure to tighten swing door fastener completely when service is completed. In addition, the burner power cord will have to be disconnected from the receptacle in the front jacket. A.
IX. SYSTEM START-UP (continued) D. START OIL BURNER. made recheck for a draft of zero inches water column ("w.c.) in the canopy. Replace plug at completion. 1. Open oil supply to burner and vent fitting on fuel pump. See Tables 15A thru 15C and 16 (at rear of this manual) for details regarding the overfire pressure when baffles are both installed and removed. 2. Turn 'On' electrical service switch to boiler. 3.
IX. SYSTEM START-UP (continued) WARNING Before installation of the boiler is considered complete, the operation of all boiler controls must be checked, particularly the primary control and high limit control. J. VERIFY HONEYWELL OIL PRIMARY FEATURES using procedures outlined in Instructions furnished with control or instructions as follows: 1. R7284 Features and Controls a. The Oil Primary is a microprocessor-based control.
IX. SYSTEM START-UP (continued) • If safety switch shuts down burner and • • • • • resistance is above 1600 OHMS, open line switch to boiler. Access cad cell under ignitor, clean face of cad cell and see that cell is securely in socket, see Figure 32. Check gasket around perimeter of ignitor lid for proper seal. If gasket is missing or damaged, replace gasket. Room light can effect cad cell resistance. Reset safety switch. Close line switch to boiler.
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 above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.
X. operating Figure 33: Boiler Control & Option Panel Orientation A. BOILER SEQUENCE OF OPERATION Table 9: Sequence of Operation 1. The boiler's sequence of operation is shown in Table 9. 2. When there is a call for heat the boiler control starts the system circulator and the thermal purge (circulator prepurge time) begins.
X. operating (continued) the trial for ignition, the oil primary control will shut the burner down and enter into a hard lockout. The Oil Primary must be reset manually before the burner can be restarted. B. USING BOILER CONTROL The Boiler Control is located under the Jacket Front Cover, to the left of the Option Panel (Refer to Figure 33). The Boiler Control display, along with Up ñ, Down ò, and “I” keys may be used to view boiler operating status (Figure 34).
X. operating (continued) F. Changing the Adjustable Parameters To adjust parameters such as the High Limit Setpoint and High Limit Differential: 1. Using the Boiler Control display, access the adjustment mode by pressing and holding the Up , Down , and “I” keys simultaneously for three (3) seconds. This procedure is intended to discourage unauthorized changes or accidental changes to limit settings. 2. Press the "I" key to display available Adjustment Mode options. Select an option.
X. operating (continued) 7. Priority Time () When the Priority Time parameter is set to “on” and Domestic Hot Water (DHW) call for heat is “on” the DHW demand will take “Priority” over home heating demand and the system circulator will be forced “off”. Priority Time ends and the system circulator is released to service home heating demand when Domestic Hot Water call for heat is over. When Priority Time parameter is set to “Off” the DHW call for heat does not force “off” the system circulator.
X. operating (continued) c. External Low Limit, Parameter ZC = ELL The boiler control is capable of functioning as a warm start control when external limit control is installed that closes a contact when boiler water temperature falls below a setpoint. When an external limit contact closes (boiler water is cold) the boiler is started and the ZC and C1 output terminals are de-energized.
XI. MAINTENANCE AND SERVICE INSTRUCTIONS A. MAINTENANCE OF LOW WATER CUT-OFF DEVICES (when installed) See Instructions provided with Low Water Cut-off Option Card for Installation Instructions. WARNING Probe type low water cut-off devices require annual inspection and maintenance. 1. PROBE TYPE LOW WATER CUT-OFF Although these devices are solid state in their operation, the probe is exposed to possible contamination in the boiler water and subject to fouling.
XI. MAINTENANCE AND SERVICE INSTRUCTIONS (continued) c. Remove relief valve using extreme care to avoid damaging it. d. Add an appropriate amount of recommended boil out compound. e. Replace relief valve. f. Fill the entire system with water. g. Start firing the boiler. h. Circulate the water through the entire system. i. Vent the system, including the radiation. j Allow boiler water to reach operating temperature, if possible. k. Continue to circulate the water for a few hours. l. Stop firing the boiler.
XII. BOILER Cleaning WARNING All boiler cleaning must be completed with burner service switch turned off. Boilers equipped with burner swing door have a potential hazard which can cause severe property damage, personal injury or loss of life if ignored. Before opening swing door, turn off service switch to boiler to prevent accidental firing of burner outside the combustion chamber. Disconnect the burner plug from the receptacle in the front jacket.
XII. BOILER Cleaning (continued) Figure 35: Cleaning of Boiler Flueways WARNING The boiler must be connected to an approved chimney in good condition. Serious property damage could result if the boiler is connected to a dirty or inadequate chimney. The interior of the chimney flue must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions.
XIII. TROUBLE SHOOTING A. COMBUSTION 1. NOZZLES — Although the nozzle is a relatively inexpensive device, its function is critical to the successful operation of the oil burner. The selection of the nozzle supplied with the MPO-IQ boiler is the result of extensive testing to obtain the best flame shape and efficient combustion. Other brands of the same spray angle and spray pattern may be used but may not perform at the expected level of CO2 and smoke.
XIII. TROUBLE SHOOTING (continued) 3. Control locks out after Trial For Ignition (TFI). a. No oil to burner. b. Shorted electrodes. c. Nozzle clogged. d. Airflow too high. e. Ignitor module defective. f. CAD cell defective. g. Oil valve stuck open or closed. Note: The Safety Monitoring Circuit (SMC) is designed to provide lockout in the event of a stuck or welded motor relay. NOTICE If flame is not established within 15 seconds of oil valve actuation (known as Trial For Ignition [TFI]) lockout will occur.
XIII. TROUBLE SHOOTING (continued) make sure that they are tight. Also, check the wiring on the boiler against the wiring diagram in Figures 28A, 28B and 28C. Ensure that incoming 120 Vac power polarity is correct and that the boiler is properly grounded. Possible ErP (External Error) Values: 4. A defective control or component is generally the least likely cause. Before replacing a component, try to rule out all other possible causes. 5.
XIII. TROUBLE SHOOTING (continued) E. Use BOILER Control Display and ErP Numbers To Direct TroubleShootinG (continued) Table 14B: external device (Oil Primary, Option Card, etc.) error numbers Display ErP 4 ErP 5 ErP ErP 10 ErP 18 Status Warning, Cad Cell Resistance High (service required) No Ignition, Check Cad Cell No Ignition, Check Cad Cell The burner lit very late during the trial for ignition and is susceptible to not lighting.
XIII. TROUBLE SHOOTING (continued) E. Use BOILER Control Display and ErP Numbers To Direct TroubleShootinG (continued) Table 14B: external device (Oil Primary, Option Card, etc.) error number (continued) Display Status Recommended Corrective Actions ErP 23 Flame was proven during the valve on delay period. Check the oil valve for proper Flame Out of Sequence, operation. During Pre-Purge If the system does not have an oil valve, set the valve on delay to 0.
XIII. TROUBLE SHOOTING (continued) F. Use Boiler Control display STA (status) Number To guide TroubleShooting The Boiler Control will flash “” followed by a number. Use this number to identify the boiler problem in the table below: 1. Burner and Circulator Off Display / Status Recommended Corrective Action The boiler has not detected a call for heat (hr = off and dh = off). Ensure there is power to the boiler control.
XIII. TROUBLE SHOOTING (continued) F. Use Boiler Control display STA (status) Number To guide TroubleShooting (continued) 5. Burner will not come on Display / Status Recommended Corrective Action When a hard lockout occurs the burner shuts down and will not restart until the Oil Primary’s manual reset button is pressed. The Oil Primary will enter the Hard Lockout mode when the burner fails to light, loses flame during run three times or senses flame during pre-purge or post purge.
XIII. TROUBLE SHOOTING (continued) G.
XIV. Repair Parts All MPO-IQ™ Boiler Repair Parts may be obtained through your local U.S. Boiler Company Wholesale distributor. Should you require assistance in locating a U.S. Boiler Company Distributor in your area, or have questions regarding the availability of U.S. Boiler Company products or repair parts, please contact U.S. Boiler Company Customer Service at (717) 481-8400 or Fax (717) 481-8408.
Bare Boiler Assembly XIV.
XIV. Repair Parts (continued) Item No. Description Part No. MPO-IQ84 MPO-IQ115 MPO-IQ147 MPO-IQ189 MPO-IQ231 1. BARE BOILER ASSEMBLY Cast Iron Block Assembly - 2 Section 1A 103071-02 1 1 --- --- --- Cast Iron Block Assembly - 3 Section 103071-03 --- --- 1 --- --- Cast Iron Block Assembly - 4 Section 103071-04 --- --- --- 1 --- Cast Iron Block Assembly - 5 Section 103071-05 --- --- --- --- 1 Spanner Bar w/Threaded Inserts, 1-1/4" x 1-1/2" x 14-3/8" Lg.
Jacket Assembly XIV.
XIV. Repair Parts (continued) Item No. Description Part No. MPO-IQ84 MPO-IQ115 MPO-IQ147 MPO-IQ189 MPO-IQ231 2.
MPO-IQ84 Thru MPO-IQ231 Water Boilers - Trim and Controls XIV.
XIV. Repair Parts (continued) Item Description No. Part No. MPO-IQ84 MPO-IQ115 MPO-IQ147 MPO-IQ189 MPO-IQ231 3. MPO-IQ84 Thru MPO-IQ231 WATER BOILERS - TRIM AND CONTROLS Beckett AFG Oil Burner w/Gasket for: Natural Draft MPO-IQ84 Spec No. BCB9502 104506-02 1 --- --- --- --- MPO-IQ115 Spec No. BCB9503 104507-02 --- 1 --- --- --- MPO-IQ147 Spec No. BCB9504 104508-03 --- --- 1 --- --- MPO-IQ189 Spec No. BCB9505 104509-04 --- --- --- 1 --- MPO-IQ231 Spec No.
XIV. Repair Parts (continued) Item No. Description Part No. MPO-IQ84 MPO-IQ115 MPO-IQ147 MPO-IQ189 MPO-IQ231 4.
XIV. Repair Parts (continued) Item No. Description Part No. MPO-IQ147 MPO-IQ189 MPO-IQ231 5.
Beckett AFG Burner XIV.
XIV. Repair Parts (continued) BECKETT AFG OIL BURNER PART NOS. FOR MPO-IQ SERIES BOILERS NATURAL DRAFT APPLICATIONS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below.
Beckett NX Burner XIV.
XIV. Repair Parts (continued) BECKETT NX OIL BURNER PART NOS. FOR MPO-IQ SERIES BOILERS DIRECT VENT APPLICATIONS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Also provide the name of the part(s) and part number as listed below. Item No.
XIV. Repair Parts (continued) RIELLO OIL BURNER PART NUMBERS FOR MPO-IQ SERIES BOILERS NOTE: When ordering parts always give the serial and model numbers shown on the boiler and burner. Refer to Models F3 & F5 Installation Manual, Riello 40 Series Residential Oil Burners (C6501010) or Model F10 Installation Manual, Riello 40 Series Residential Oil Burners (2902554) for an exploded view of the burner and a list of spare parts.
XV. BURNER SPECIFICATIONS Table 15A: Beckett AFG burner specifications - chimney vent Boiler Model Burner Input (GPH) Burner Model MPO-IQ84 0.60 AFG MPO-IQ115 0.80 AFG MPO-IQ147 1.05 AFG MPO-IQ189 1.35 AFG MPO-IQ231 1.65 AFG Approx. Approx. Approx. Air Pump Head Insertion Baffle Stack Temp. Breech Air Band Shipped Location Increase Shutter Pressure Type Depth Pressure (setting) CO2 (setting) (PSI) (setting) (Inch) (pass) Without (%) (" w.c.) (3) Baffles °F (2) Nozzle 0.
XV. BURNER SPECIFICATIONS (continued) Table 15C: CARLIN EZ burner specifications - chimney vent Boiler Model Burner Input (GPH) Burner Model MPO-IQ84 0.60 EZ-LF MPO-IQ115 0.80 EZ-LF MPO-IQ147 1.05 EZ-66 MPO-IQ189 1.35 EZ-66 MPO-IQ231 1.65 EZ-66 Pump Head Air Pressure Setting Setting (PSI) Nozzle 0.50 x 60AS Danfoss 0.65 x 60AS Danfoss 0.85 x 45AS Danfoss 1.10 x 45B Delavan 1.35 x 45B Hago Insertion Air Tube Depth Type (Inch) Approx. Shipped CO2 (%) Approx. Approx. Baffle Stack Temp.
APPENDIX A – Oil Boiler iq control system IQ Control System Overview MPO-IQ Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ Control System" consists of an IQ Oil Boiler Control in conjunction with an Oil Primary Control and an IQ Option Panel with optional "plug-in" IQ Option Cards. The IQ Control System fully integrates both factory and field installed components, simplifying installation and troubleshooting.
APPENDIX A – Oil Boiler iq control system (continued) IQ Option Panel: P/N 102291-01 The IQ Option Panel works together with the IQ Oil Boiler Control to provide an easy and convenient means to add factory-engineered auxiliary boiler control features. When installed into the IQ Option Panel, IQ Option Cards provide plug-'n-play high temperature limit, low water cut-off and outdoor reset controls.
APPENDIX A – Oil Boiler iq control system (continued) Hi Limit IQ Option Card (Auto Reset): P/N 102717-01 Hi Limit IQ Option Card (Manual Reset): P/N 102720-01 High Limit IQ Option Cards add auxiliary temperature limit-rated controls to MPO-IQ Boilers. High Limit IQ Option Cards plug into the IQ Option Panel and connect to a system-mounted probe with a single Molex connection. High Limit IQ Option Cards feature an adjustable set point and differential, as well as built-in diagnostics.
APPENDIX A – Oil Boiler iq control system (continued) SYSTEM PARTS LIST Factory Mounted Components Part Number Item Description 103851-01 IQ Oil Boiler Control (2012) 120V, less well, Hi Limit 180°F (Default), Hi Limit Range (140° - 240°F), Hi Limit Differential 15°F (Default), Hi Limit Diff Range (10° - 30°F). Includes 12" Limit Rated Temperature Sensor, Honeywell P/N 5001464-001. 103195-01 Limit Rated Temperature Sensor, 12" length.
APPENDIX B – FIGURES Figure Number Page Number Figure 1 6 Description MPO-IQ84 Thru MPO-IQ231 Water Boiler Section I - Pre-Installation Figure 2A 8 Chimney Vented Boiler - Minimum Installation Clearances to Combustible Materials (Inches) Figure 2B 9 Direct Vent Boiler - Minimum Installation Clearances to Combustible Materials (Inches) Section II - Packaged Boiler Assembly - Trim & Controls Figure 3 11 Packaged Boiler Removal from Skid Figure 4A 12 Partial Front View - Burner Swing Door Mount
APPENDIX B – FIGURES (continued) Figure Number Page Number Description Section VII - Electrical Figure 28A 42 Schematic Wiring Diagram Figure 28B 43 Schematic Wiring Diagram, Burner Options Figure 28C 44 Ladder Diagram Section VIII - Oil Piping Figure 29 45 Single Pipe Oil Line Figure 30 46 Two Pipe Oil Lines Section IX - System Start-Up Figure 31 49 R7284 Terminals, Display and Reset Button Figure 32 50 Cad Cell Location Section X - Operating Figure 33 52 Boiler Control & Option P
APPENDIX c – TABLES Table Number Page Number Description 1A 7 Dimensional Data 1B 7 Rating Data Section I - Pre-Installation Table 2 10 Direct Vent Configuration Components Section II - Packaged Boiler Assembly - Trim & Controls Table 3 17 Baffle Usage Section IV - Water Boiler Piping Table 4 26 Minimum Flow Rate Section VI - Direct Venting / Air Intake Piping Table 5 35 Wall Cutout Dimensions Table 6 37 Flex Vent / Vent Termination Pipe Diameters Section VIII - Oil Piping Table 7 4
U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.
